Move-in of a pharmaceutical system for aseptic filling of vaccines

Unstoppable by snow and storms: No matter how detailed the transport planning and how well-prepared the construction site, there can still be surprises on a project. On this job, the weather tried to play tricks on the SCHOLPP fitters from Dietzenbach, but without success. Although the logistics process faltered at times, the agreed deadlines were still met.

On the agenda was the transportation and move-in of a complete pharmaceutical filling system for injection vials (vaccines). It was destined for IDT Biologika GmbH in Dessau-Roßlau/Saxony-Anhalt. SCHOLPP’s customer was the system manufacturer, Syntegon Technology GmbH in Crailsheim/Baden-Württemberg.

SCHOLPP Dietzenbach: Extensive experience in the pharmaceutical industry

The job was assigned to the SCHOLPP Dietzenbach team, who can look back on many years of experience with pharmaceutical technology and with move-ins and installations in cleanrooms. On these projects, the SCHOLPP fitters are usually faced with very complex technical systems that require extremely careful handling. What’s more, the pharmaceutical companies’ cleanroom protocols must be strictly followed.

Complete service: Logistics planning, transportation, and installation

SCHOLPP collected the complete system and transported it by truck. The heaviest component of the pharmaceutical filling system for IDT in Dessau weighed 8.7 metric tons. A total of 20 large components (max. 6.80 x 2.40 x 3.00 meters), plus various accessories, with a total weight of 51 metric tons had to be brought into the IDT plant. Nine truckloads were required to transport them from the Syntegon manufacturing plant in Crailsheim to Dessau, 420 km away.

Move-in at a great height: Crane operator without visual contact

A particular problem when moving the system into the pharmaceutical plant in Dessau was that all the system components had to be transported using a truck-mounted crane (160 metric tons) through a roof opening (3.0 x 8.0 meters) at a height of 18 meters. The crane had a reach of up to 20 meters. Since he had no visual contact with the roof opening, the crane operator was given precise instructions by the site manager. Once inside the building, the components had to be lowered another two levels.

The SCHOLPP fitters had prepared the cleanroom in the pharmaceutical plant in accordance with the specifications of the customer, IDT Biologika. The positioning of all components was planned and mapped out. Things became rather cramped at times as more plant components arrived. Soon there was little room left for maneuvering with the heavy-duty moving skates. Industry experience, a clever approach, and skilled fitters’ hands were needed here.

Sophisticated logistics defy storm and snow

Good logistical planning was therefore essential. This was prepared by the SCHOLPP engineering team in advance and coordinated with the system manufacturer Syntegon and the customer IDT Biologika. The arrival of the transports in Dessau had to be scheduled down to the hour since no intermediate storage space was available. The upper system components were lifted with chain hoists and placed precisely onto the lower components. And then there was the weather. At times, wind and snow prevented some components from being moved in at such lofty heights. Nevertheless, our team was able to meet all the agreed deadlines.