MERCK – Industrial Transfer

Completion of the industrial transfer of a nanosphere and polymer microsphere manufacturing unit.

Location : Meyzieu, Rhône FRANCE
Project phases : Detailed design and implementation (studies and monitoring of the transfer)
Project duration : 3-month detailed design and 18-month implementation

Within the MERCK group, the ESTAPOR division has been designing and manufacturing nanospheres and microspheres of polymers, magnetic or not, since 1993.

MERCK wanted to regroup ESTAPOR’s premises, initially in Pithiviers, on its Meyzieu site. For this purpose, MERCK had decided to rely on the services of an industrial engineering team to confirm the preliminary design studies and manage the complete transfer, from the shutdown of the units and the management of the stocks before transfer to the complete reassembly on the host site. The transfer concerned the two ESTAPOR businesses: laboratory (clean rooms) and production (grey rooms). The reception site was completely dismantled since the previous activity was still in place on the floors.

Studies :

  • Transfer of incorrect existing PIDs
  • Miscellaneous list: equipment, piping, cables
  • Fluid balance assessment
  • Assessment of the premises under controlled atmosphere HVAC)
  • Single line diagrams of electrical connections
  • Implantations and facade plans for the architect’s file:
    • Laboratory part with type constraints: place on benches, hot, cold, compressed air, nitrogen, purified water, safety showers
    • Workshop part with type constraints: staff flows, material flows (no crossing of certain clean and dirty flows), maintainability, future evolution towards several parallel lines, integration of grey rooms and air handling units
  • Presentation of these studies to the other actors of the project: ESTAPOR France client, MERCK Germany decision-maker, MERCK France host site, local architect
  • Control-command architecture
  • Functional analysis
  • Allocation
  • Interface tables for all fluids, high and low current electricity, ESP
  • Interface positioning plan
  • CAPEX
  • Planning
  • Lots concerned :
    • Dismantling and preparation of the reception building
    • Industrial transfer
    • Civil engineering and soil studies
    • Electricity / Instrumentation / Automation
    • HVAC and cold room 120m²
    • Laboratory furniture and articulated arms
    • Piping system
    • Glass reactors

Realization :

  • Drafting of order specifications: equipment and works contracts
  • Assistance in placing orders
  • Follow-up of supplier and construction company studies
  • Budget monitoring
  • Follow-up of the planning
  • Realization of the inventory plans
  • Facilitation and writing of site reports
  • Completion receipts
  • Establishment and follow-up of reserve lists

Total amount of the project :

Range A < €10 million
Range B: between €10 and €20 million
Range C: between €20 and €50 million
Range D > €50 million

You can find our different realizations on chemistry and innovative materials by clicking on the following link.