Pharma Factory Layout Design for Setting Up Pharma Facility
Pharma Factory Layout Design Service for Manufacturing High-Quality, Effective, and Safe Drugs
The pharmaceutical industry is highly regulated owing to its impact on public health. The safety, quality, and efficacy of drugs determine the patient outcome. Furthermore, the drug manufacturing process and the pharmaceutical manufacturing facility affect these attributes of the drug. Thus, carefully planning and various factors have to be taken into consideration while designing pharma plant layout. Hence, extensive regulatory and industry guidelines are in place for pharma factory layout design. Therefore, designing pharma manufacturing factories requires industry knowledge and expertise in regulatory guidelines. Designing pharma plant layout is a multifaceted and complex process. Avail our pharma factory layout design service to have an efficient, regulatory compliant, sustainable, scalable, safe, and future ready facility. Having designed over 500 factories, since 2007, we provide the best-in-class service in the pharmaceutical industry.
Major Factors to Consider When Designing Pharma Plant Layout
- Nature of the product: The pharma factory layout design has to be primarily planned depending on the nature of product to be manufactured.
- Manufacturing process and production volume: The drug manufacturing process is another major factor to take into consideration while designing pharma plant layout. Notably, effective and efficient production process flow will be required to prevent cross contamination. Additionally, the production volume has to be taken into consideration. Sufficient space should be available to house raw materials, machinery, finished products.
- Land location and factory building: The location of the proposed pharmaceutical manufacturing site and area available are vital factors to focus on. Maximum utilization of available space is required. The factory building shape and size will have to be taken into consideration while planning the pharmaceutical manufacturing facility design.
- Machinery and equipment: The machinery and equipment to be used as well as the space required to handle and accommodate them are vital factors. Moreover, sufficient space should be present between equipment to prevent accidents during operations. Hence, the pharma factory layout will depend on the machinery and equipment required for your production process.
- Budget and expenses: Factory construction, operation, and maintenance costs will all add to the expenses of starting and establishing a pharmaceutical factory. Hence, last but not the least, the budget has to be taken into consideration.
Pharma Factory Layout Design: Key Parameters
Various stringent regulatory guidelines are in place for pharmaceutical manufacturing facilities. While designing pharma manufacturing factories, certain key parameters have to be kept in mind. The pharmaceutical manufacturing facility design determines the final quality, safety, and efficacy of the drugs. The pharma plant layout design is the floor plan of a pharmaceutical manufacturing site. The design is used to plan the effective utilization of the facility space and arrangement of machinery and equipment. The layout has to be meticulously planned to optimize efficiency without compromising safety or quality. Also, the layout design should focus on avoiding safety hazards and contamination risks. Moreover, the focus of the manufacturing facility design should be to streamline the production process and ensure the efficient flow of materials and personnel. We have listed some of the key parameters of a pharma plant layout design.
Key elements that have a vital role in pharma factory layout design
Pharma factory layout design planning must focus on material flow
Efficient and unidirectional flow of materials have to be ingrained in the pharma factory layout design to avoid operational bottlenecks and cross-contamination. Additionally, it enhances overall safety.
Equipment selection and placement
Depending on the product and the manufacturing process, the equipment and machinery have to be selected. Selecting the appropriate equipment is a vital aspect of pharma factory layout design planning. Also, the level of automation and scalability have to be taken into consideration. Moreover, the layout has to be strategically designed to efficiently utilize the space. The equipment has to be placed and arranged in a manner that will not disrupt operations or lead to cross-contamination.
Quality control units
The quality control labs are critical components of any pharma manufacturing facility. High-precision instruments and equipment will be required to rigorously test the quality and safety of pharmaceutical products. Thus, dedicated quality control units will be required to analyze the products.
Cleanrooms
Clean rooms form the core of the pharma manufacturing facility. It provides a clean, regulated, and sterile environment that is required for the different steps of the pharma production. Moreover, cleanrooms will have to be designed as per industry guidelines, ISO 14644 guidelines.
HVAC systems
Heating, Ventilation, and Air Conditioning (HVAC) systems are required to maintain controlled environments. These systems form a part of containment measures and cross-contamination prevention strategy. Hence, the HVAC systems have to be properly designed and integrated into the manufacturing facility, owing to their vital role in pharmaceutical production.
Technology for efficient production
Advancement in pharmaceutical production technology is proving a boon for the pharma sector. Hence, while designing pharma manufacturing factories, technology should be ingrained in these factories. Technology can be used for inventory management, regulatory compliance, quality management, traceability, and automation of production lines.
Sustainable and scalable factories
Pharma factories have to be designed with sustainability in mind. Sustainable practices that will reduce environmental impact have to be incorporated in pharma manufacturing facilities. Furthermore, the plant design should incorporate flexibility and scalability. There should be a provision to scale up or scale down the factory as per requirements.
Regulatory compliance is a critical component of pharma factory layout design
The pharmaceutical industry is stringently regulated. Regulatory bodies, such as the U.S. FDA, EMA, CDSCO, strictly regulates the pharma sector to safeguard the public health. Hence, the pharma factory layout design has to comply with the WHO GMP, Drugs and Cosmetics Rules, and other applicable CDSCO guidelines. Â Thus, in-depth understanding of the regulatory frameworks as well as Good Manufacturing Practices (GMP), Good Laboratory Practices (GLP), and Good Distribution Practices (GDP) are required while designing pharma factories. Ensuring regulatory compliance is the most important element of designing pharma plant layout.
Pharmaceutical manufacturing facilities designed by our experts will be regulatory compliant, sustainable, scalable, safe, efficient, and future ready.
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Our Comprehensive Pharma Factory Layout Service
We offer all-encompassing pharma factory layout service tailored to your preference and requirements. We have presented the parameters Pharmadocx Consultants’ pharma plant layout service will cover.
Site plan
We provide a site layout in AutoCAD format fully compliant with MDR 2017 requirements. Additionally, we will incorporate view panels on the walls to ensure clear visibility of the production area. We provide door sizes and opening directions aligned with air movement patterns to prevent cross-contamination. Moreover, we will design door placements according to operational usage and regulatory standards.
 Flooring layout
We will provide layouts showing areas designated for epoxy flooring. We will mark zones where Kota Stone, Tiles, or Vinyl Flooring are to be installed. We provide color-coded differentiation to ensure clarity in flooring types across the facility. We will deliver precise flooring layouts to support GMP compliance and durability.
False ceiling layout
We provide ceiling layouts with height variations based on machine requirements. We will highlight areas where false ceilings are required and where they are not. We provide color-coded ceiling height indicators such as 9 feet, 11 feet, or no ceiling. Furthermore, we will ensure ceiling designs meet both operational and regulatory standards.
Type of false ceiling layout
Our pharma factory layout service package also specifies the type of false ceiling required in each area. We will highlight ceiling types, such as Sandwich Panel, Gypsum, Calcium Silicate, POP, or PVC. We provide color-coded differentiation for easy identification of ceiling materials. We will ensure ceiling types are selected based on GMP and functional suitability.
Wall and sandwich panel colour marking layout
We provide layouts with color-coded walls for GMP Sandwich panels or aluminum partitions. We will guide the selection of GMP panels, such as PCGI or PPGI sheets. We provide options for panel fillings including PUF, Rockwool, or Honeycomb. We will ensure wall paneling meets GMP standards and client preferences.
Man and material flow layout
We provide separate drawings for man movement across each floor. We will deliver layouts for material movement, including raw, packing, finished, and semi-finished goods. We provide defined scrap movement drawings with disposal areas as per international guidelines. Moreover, we will ensure flow layouts minimize contamination risks and maximize efficiency.
Electric point details
Our pharma factory layout service covers markings for electric points for machines, pass boxes, LAF, and fly killers. We will deliver machine-wise and floor-wise electrical power requirements for the plant. We provide consolidated electrical input sufficient for contractor quotations and execution. We will coordinate with electrical consultants for detailed layouts and cabling requirements.
HVAC AHU details
We provide room data sheets for HVAC including class, pressure, temperature, humidity, and occupancy. We will deliver specifications for room dimensions, area, and volume to support HVAC design. We provide environmental specifications sufficient for HVAC consultants to prepare quotes and drawings. We will ensure HVAC inputs align with production, warehouse, and laboratory requirements.
Pressure zoning layout
We provide layouts defining pressure levels for each room. Additionally, we will highlight which rooms are negative pressure zones. We provide zoning for corridors and airlocks as positive pressure areas. We will ensure pressure zoning supports contamination control and regulatory compliance.
Air handling unit (AHU) zoning
We provide layouts showing the coverage area of each AHU. We will highlight AHU zones with individual colors for clarity. We will provide identification of AHU numbers linked to specific areas. We will ensure AHU zoning supports efficient HVAC management.
Area classification layout
We provide layouts marking Class D, Class C, and Class B areas. We will ensure classifications are aligned with Schedule M guidelines. We provide clear demarcation of cleanroom classifications for compliance. We will deliver layouts that support GMP and regulatory audits.
Plumbing details
We provide layouts marking points for purified water and raw water supply. We will highlight drain points and chilled water connections. We provide layouts for compressed air, nitrogen, vacuum, and steam supply. We will ensure plumbing layouts meet operational and safety requirements.
Room No. layout
We provide room numbers for each designated space in the facility. We will deliver layouts with clear numbering for easy identification. We provide systematic room numbering to support documentation and audits. We will ensure room layouts are aligned with workflow and compliance needs.
Pass box No. and dimensions layout
We provide layouts specifying static, dynamic, and multi-door pass boxes. We will deliver pass box dimensions suited to their intended use. We provide door opening directions based on location and workflow. We will ensure pass box layouts meet GMP and contamination control standards.
List of machines
We provide a detailed list of machines required for the facility. We will include instruments and equipment specifications in the list. We provide machine details aligned with production and compliance needs. We will ensure the machine list supports procurement and installation planning.
Why Choose Pharmadocx Consultants for Designing Pharma Plant Layout?
Our pharma plant layout design process is in-depth and does not stop at just designing the pharmaceutical facility. We provide ongoing support for any future needs as well. First, we understand your operational needs and factory requirements. Second, our team of experts will draft an initial plant layout and send you a blueprint of the potential facility design. Then, based on your feedback and inputs, we will modify the proposed designs. We use an iterative approach to ensure our proposed design achieves your long-term vision. Finally, we offer ongoing support for any future modifications. Our support goes beyond delivering the final plant layout design. We try to establish a long-term collaboration with our clients.
- Customer-centric approach and tailored service: Every plant design is unique, owing to varying customer requirements. Hence, we tailor our services accordingly.
- Best in class service: Having worked in this industry since 2007, successfully designing over 500 factories, we have extensive expertise in designing pharma manufacturing factories.
- Experienced team: With a dedicated team of seasoned experts, we are one of the best in the field. Using state-of-the-art design tools, we will leverage our expertise to design your plant.
- Plants with efficiency and sustainability at its core: Pharma plants designed by us are sustainable and energy efficient. Additionally, they are designed to be flexible and scalable.
- Effective space utilization: Our plant designs ensure maximum utilization of every square foot of the site, leaving no space underutilized. While designing the plant, we focus on optimum utilization of the space.
Having designed pharma plant layouts since 2007, we have successfully designed over 500 pharmaceutical factories. By availing our pharma factory layout design service, you can ensure regulatory compliance, operational efficiency, and cost-effective production.
Let's Talk!
We'd love to hear from you! Whether you have questions about our pharmaceutical plant setup consultation services or want to discuss a potential project, our team is here to help. Simply fill out the form below, and we'll get back to you as soon as possible. Alternatively, you can reach out to us directly using the phone number or email address listed on this page. We look forward to connecting with you!
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- Head Office - Opposite Dewan Mill, Old D.C. Road Sonepat - 131001 Haryana, India
- Registered Office - Netaji Subhash Place, Delhi, 110034
We also specialize in
Medical Device Factory Layout Design
Cosmetics Factory Layout Design
Nutraceutical Factory Layout Design