End-to-End IV Production
PW/WFI generation → solution preparation → ISPM molding/filling → terminal sterilization → inspection → packing → controlled storage.
3D Visual Master Gallery for CEO
Project Aqua Pure IV Manufacturing Facility - Campus Architecture & Complete 3D Renderings
Campus Architecture & Master Site Concept (Sheikhupura Site)
195,050 sq. ft. usable site area (35.0 Kanals) with 138,335 sq. ft. building footprint, glass facade administration, dedicated truck logistics bays, and high-density finished goods storage (3,564 Pallets).
CEO 4K Presentation Master Board
Executive Overview Board for CEO Presentation Room • Highfine Group / Bolton Pharma Project Baseline.
Executive Project Proposal Presentation Board
End-to-End ISBM All-in-One Machinery Schematics, Cleanroom Facility Zoning, and Automated Robotic Workflow.
1. ISBM (Injection Stretch Blow Molding) All-in-One Line
Drawing: M-F26002注吹灌布局.dwg • Continuous preform molding, blow-fill-seal, and capping.
2. Purified Water (PW) & WFI Generation Room
Drawings: water system layout(1).dwg & Horizontal WFI tank 10T/20T • RO plant, Multi-Effect WFI distiller, 10T/20T WFI tanks, CIP skid.
3. Solution Compounding & Preparation Suite
Drawing: Manufacturing & Holding PG15T3.dwg • Twin 15,000L PG15T3 mixing vessels, 3m steel platform, API charging tanks.
4. Terminal Sterilization & Autoclave Suite
Drawing: Autoclave room layout 2025.12.14.dwg • Water-bath sterilizer, sterilizer carts, control room monitoring station.
5. Automatic Visual Inspection Machine (24,000 BPH)
Drawing: External Dimension of VIM (24000BPH).pdf • 24,000 BPH optical VIM inspector, dual re-inspection conveyor lines.
6. High-Speed Packaging & EFORT Robotics
Drawing: Packing Line 巴基斯坦最新方案.dwg • EFORT ER210-2700 6-Axis Palletizing Robot • Speed ≥400 bpm.
BTI Complete Image Board Suite
11 Full-Resolution Technical Presentation Boards
01. Option D3 Exterior Campus Master Architectural Board
190,780 sq. ft. dual-train expanded campus architectural rendering, security gates, and 35.00 Kanal perimeter layout.
02. Option D3 Interior Cleanroom Features Board
Cleanroom ISO 5 filling core, Grade B/C gowning airlocks, dual packaging halls, and warehouse layout for Option AQI-D3.
03. Option D4 Exterior Phased Campus Master Architectural Board
138,335 sq. ft. compact phased campus architectural rendering with high-density warehouse shell.
04. Option D4 Interior High-Density Features Board
High-density 3,564 pallet storage racking system (+200% capacity), ISBM BFS core, and compact utility block.
05. High-Speed Packaging Line & EFORT Robotics Board
EFORT ER210-2700 6-axis industrial palletizing robot, JDZ-320P continuous cartoning, pillow packers ($\ge 400\text{ bpm}$).
06. ISBM (Injection Stretch Blow Molding) All-in-One Machinery Board
Integrated single-step preform molding, stretch blow molding, sterile IV solution filling, and capping line.
07. Solution Compounding PG15T3 & Operating Platform Board
Twin 15,000L PG15T3 jacketed stainless steel compounding vessels, 3.0m elevated SS platform, API vacuum charging receiver.
08. Water-Bath Autoclave & Terminal Sterilization Suite Board
Water-bath overpressure sterilizers ($121^\circ\text{C}$), sterilizer carts, control room computer monitoring station.
09. Automatic Visual Inspection Machine (24,000 BPH) Board
High-speed 24,000 BPH optical VIM inspector, dual re-inspection conveyor lines, electrical cabinets.
10. Purified Water (PW) & WFI Water System Board
10,000 L/h RO plant, 6,000 L/h Multi-effect WFI distiller, CIP sanitary cleaning skid.
11. Horizontal WFI 10-Ton & 20-Ton Storage Tank Vessel Board
Sanitary SS316L 10,000L & 20,000L horizontal WFI storage vessels with $80^\circ\text{C}$ hot loop distribution.
FROM DESIGN INTENT TO FIELD EXECUTION
Issued-for-Construction Master Drawing Suites
Coordinated architectural, process, HVAC, clean-utility, electrical, fire-life-safety and automation information for disciplined project delivery.
Issued-for-Construction (IFC) Master Drawing Suites
Click Any Discipline Card Below To Open Full Specifications
COMPLETE DELIVERY FRAMEWORK
12 Master Engineering, Validation & Regulatory Packages
A single controlled framework connecting design basis, construction, commissioning, qualification, contamination control and DRAP/PIC/S readiness.
12 Master Engineering, Validation & Regulatory Packages
Click Any Package Card Below To Open Interactive ModalPersonnel Change Room Architecture & Visual Renders
Grade D Outer PAL & Hand Wash Station
Sensor-activated hands-free wash basin, HEPA warm-air hand dryer, and Step-Over Bench (SOB 1). Sinks are restricted to Grade D only as per EU Annex 1.
Grade B/C Interlocked Gowning Airlock
Step-over bench (SOB 2 & 3), continuous filament sterile jumpsuit gowning, electromagnetic door interlocks with LED status lights, and sensor IPA hand rub.
Step 1
CNC Outer Locker
Street clothing & outdoor shoe removal. Hairnet application.
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Step 2 (SOB 1)
Grade D Outer PAL
Step-over bench 1. Hand wash, HEPA dryer, Grade D coat & shoes. Sensor IPA rub.
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Step 3 (SOB 2)
Grade C Intermediate
Step-over bench 2. Non-linting jumpsuit, hood, goggles, clean boots & nitrile gloves. (No sinks).
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Step 4 (SOB 3)
Grade B Sterile PAL
Step-over bench 3. Sterile jumpsuit, sterile over-boots, sterile surgical gloves & IPA spray purge.
EU GMP Annex 1 & WHO TRS Compliance Rules
- No Sinks in Grade C/B: Hand washing sinks and HEPA dryers are strictly limited to Grade D PAL. Sinks forbidden in C & B changing rooms to prevent microbial contamination.
- Door Interlocks & Purge Timer: Electromagnetic interlocks prevent opening outer and inner doors simultaneously. 30–45s air flush cycle.
- Unidirectional Exit PAL: Separate Exit Personnel Airlock with reverse de-gowning sequence prevents cross-contamination.
PROJECT AQUA PURE • EXECUTIVE INVESTMENT CASE
Integrated sterile IV manufacturing campus designed around scalable capacity, PIC/S compliance and controlled lifecycle delivery.
The proposal brings the full manufacturing chain onto one coordinated campus: pharmaceutical water generation, compounding and holding, ISPM all-in-one blow–fill, terminal sterilization, 24,000 BPH visual inspection, robotic secondary packing and high-density finished-goods storage. D3 establishes the baseline configuration; D4 develops the strategic expansion case with two machine trains and approximately twice the production capacity.
01Patient-safe sterile process architecture
02Double-train D4 production resilience
03PIC/S-aligned validation lifecycle
04Utility and warehouse scalability
📍 Confirmed Project Site Location & Satellite Map Preview
Butt Chemicals Pvt Ltd, 31 km Lahore–Sheikhupura–Faisalabad Road, Harriya Tibbi, Sheikhupura, Punjab, Pakistan
Contamination Control by Design
Grade A/B/C/D zoning, pressure cascades, PAL/MAL segregation, hygienic utilities, environmental monitoring and traceable automation.
12 Master Packages
Design basis, architecture, PFD/P&IDs, HVAC, electrical, utilities, life safety, validation, CCS, DRAP dossier, BOQ and execution planning.
Total Plot Area
195,050 sq. ft.
VIM Inspection Speed
24,000 BPH
Packaging Speed
≥ 400 BPM
Warehouse Pallets (D4)
3,564 Pallets
Facility Scope & Capabilities
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Site Location: Butt Chemicals Pvt Ltd Campus (31.457280° N, 74.301440° E).
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ISBM Technology: Injection Stretch Blow Molding (ISBM) & Blow-Fill-Seal all-in-one production line.
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High-Speed Robotics: EFORT ER210-2700 6-axis industrial robot for automated carton palletizing.
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Pyrogen-Free Water System: Multi-effect distillation with 10-Ton & 20-Ton WFI storage tanks.
Key Cleanroom Zoning
EXECUTIVE COMPARISON
AQI-D3 baseline versus AQI-D4 double-train capacity strategy
D3 provides the reference plant arrangement and a lower-complexity operating baseline. D4 is configured as the strategic growth option with two ISPM production trains, duplicated critical downstream equipment and approximately twice the nominal manufacturing capacity, subject to final vendor guarantees and detailed utility confirmation.
D4 PRODUCTION BASIS2×Machines & nominal capacity
Comprehensive Multi-Dimensional Master Plan Evaluation: AQI-D3 vs AQI-D4
Executive Decision Matrix
Option AQI-D3 Architectural Layout
Baseline manufacturing configuration • Reference cleanroom and logistics concept • Lower initial operating complexity.
Option AQI-D4 Architectural Layout
Two production-machine trains • Approximately 2× nominal manufacturing capacity • 3,564-pallet high-density warehouse.
| Evaluation Metric / Domain | Option AQI-D3 (Baseline) | Option AQI-D4 (Double Train) | Engineering Advantage / Variance |
|---|---|---|---|
| Total Building Footprint | 190,780 sq. ft. (35.00 Kanals) | 138,335 sq. ft. (25.40 Kanals) | AQI-D4 saves 52,445 sq. ft. (-27.5% Civil Footprint) |
| Production Area | Single reference production train | Two coordinated production trains | D4 provides approximately 2× nominal line capacity |
| Finished Goods Storage | 52,420 sq. ft. (Standard Racking) | 52,780 sq. ft. (High-Bay Drive-In) | Equal area, but 3x capacity in D4 |
| Pallet Storage Capacity | 1,188 Pallet Positions | 3,564 Pallet Positions | AQI-D4 increases storage by +200% (+2,376 slots) |
| PW / WFI Peak Demand | Single-train demand basis | Double-train diversified peak demand | D4 utilities must be sized for two trains, diversity, redundancy and future margin |
| WFI Storage Duty | Single-train duty with defined reserve | 10T/20T coordinated duty/standby philosophy for double-train operation | D4 provides stronger continuity; generation and loop recovery require detailed verification |
| Electrical Maximum Demand | Single-train connected-load basis | Two-train load plus N+1 critical systems | D4 requires enlarged transformer, generator, UPS and distribution architecture |
| Primary ISPM Equipment | 1 complete all-in-one blow–fill train | 2 complete all-in-one blow–fill trains | D4 doubles nominal filling availability and enables campaign flexibility |
| Downstream Equipment | Single sterilization, inspection and packing stream | Duplicated or capacity-matched autoclave, VIM and packing streams | D4 avoids a downstream bottleneck against two upstream machines |
| HVAC & Cleanroom Strategy | Fewer classified suites and AHU systems | Two production zones with segregated or resilient AHU architecture | D4 improves maintainability but increases qualification scope and energy duty |
| Business Continuity | Higher dependency on the single production train | One train can support production while the second is maintained or changed over | D4 materially improves operational resilience |
| Validation Program | One equipment and process qualification stream | Two equipment trains plus equivalence, bracketing and concurrent readiness strategy | D4 requires a larger DQ/IQ/OQ/PQ, APS and CSV program |
| Recommended Decision Gate | Preferred where market demand supports one line and capital must be minimized | Preferred where forecast demand, exports and continuity justify two lines | Freeze after vendor throughput guarantees, SKU mix, utility balance and financial model |
| Phased Capital Strategy | Lower equipment count and simpler initial qualification | Higher initial equipment CAPEX with double-output potential | D4 recommended where demand supports 2× capacity and stronger redundancy |
Equipment Bill of Quantities (BOQ)
| Tag | Equipment Name | Specification / Capacity | Qty | Cleanroom Zone | Utility Connections |
|---|
Central Engineering Utilities
Electrical Power
380V, 50Hz, 3-Phase 5-Wire System connected to control cabinets.
Compressed Air
DN15 connection, 6 – 8 bar operating pressure for solenoid valves.
Industrial Steam
3 – 8 bar operating pressure; requires dedicated condensate discharge.
Raw & Pure Water
DN50 raw inlet at 2–4 bar; SS316L loop distribution for PW & WFI.
Civil & HVAC Criteria
Ceiling Clear Height
≥ 6.0 Meters
Max Room Temp
< 30°C
Clean Corridor Width
2,500 mm (2.5m)
Floor Drains
SS Ø100 mm
Drainage Piping
Concentrated SS Pipe