Aesica Pharmaceutical


Aesica Pharmaceutical


Plant Cooling Tower Replacement

The Client

Aesica Pharmaceuticals is one of the world’s leading pharmaceutical manufacturers, exporting to leading pharmaceutical companies across more than 30 countries.

Aesica was founded in 2004 when management acquired a BASF facility in Cramlington, Northumberland. Now employing 1,300 people across five development and manufacturing sites in the UK, Germany and Italy.

Aesica develops and manufactures primary (API) and secondary stage (finished product dosage form) pharmaceuticals, partnering with pharmaceutical companies throughout the key stages of a drug’s life cycle to supply product from initial development through to final commercial supply.

The Project

The original enquiry from the client was to look at the potential refurbishment of the water distribution systems on the three existing cross-flow cooling towers. On closer inspection, these were seen to be beyond repair where it was recommended and agreed that replacement of the towers was the most economical way forward.

The project then entailed the design, manufacture and installation of GRP replacement new cooling towers to be sited over the clients existing pond while ensuring the whole replacement tower operation was completed with the minimum of production down time.

Watermiser worked closely with the client to arrive at a bespoke design that allowed the replacement GRP cooling towers to sit above the existing concrete pond as requested. This included the design and manufacture of a suitable galvanised support steelwork structure that not only supported the cooling towers but also the new high level access structure and also the clients existing access walkway which was to be retained at the rear of the towers.

The scope included the selection, sizing, design, manufacture, off-loading and positioning of the towers, support steelwork, base frames, GRP hand railing and high-level access structure, as well as incorporation of the client’s access walkway.

The Product

We manufactured and supplied a Watermiser No 18 GRP forced draught cooling tower with direct drive axial fans. This model comprises 3 cells which can be isolated individually for cleaning and inspection, thereby minimising process down time.

The cooling tower offered was manufactured in glass reinforced plastic (GRP), a material that is completely inert to attack by any type of sterilising chemical or water treatment regime and is exceptionally benign and sustainable.

The high level galvanised steel access platform is complete with a vertical hooped ladder, safety cages, self-closing gates, open mesh flooring and kick plates. This platform together with the high level, peripheral GRP hand railing will provide a safe working area for inspection and maintenance of the drift eliminators and water distribution system, and similarly the top level of the heat transfer pack.

The Result

The towers are successfully installed and are in operation, supporting the Cramlington pharmaceutical facility.

Both client and Watermiser are happy with the result – the photos show the difference.

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