From skids to full-scale EPCM: Facility revamp for veterinary biotech completed on schedule.

In August 2020, a leading veterinary product manufacturer commissioned ZETA to deliver and integrate several purification skids at its UK production site. What began as a focused equipment delivery evolved into a full-scale EPCM (Engineering, Procurement, and Construction Management) project. ZETA’s scope quadrupled, encompassing a complete overhaul of the downstream suite, infrastructure upgrades, and cleanroom modernization – all within the original timeline.

The project presented a series of formidable challenges for the customer and the ZETA team. What began as a straightforward equipment integration quickly evolved into a full-scale facility revamp, significantly expanding the project scope while the original delivery timeline remained unchanged.

From the outset, the project encountered delays. The initial decontamination of the existing facility using vaporized hydrogen peroxide failed, postponing the start of on-site activities. Upon arrival, the team discovered severe water leakage and a saturated, deteriorated screed beneath the production floor, necessitating a complete replacement. Traditional screed would have required a 12-week drying period – an unacceptable delay given the tight schedule.

The lack of reliable documentation for the existing facility added another layer of complexity. The team had to work without accurate records of the plant layout or piping systems, making the revamp of the downstream suite particularly demanding. Additionally, the facility had to comply with SAPO 4 biosafety regulations, requiring specialized containment measures such as bunded flooring and water impermeability testing.

To overcome the deteriorated flooring issue, ZETA proposed a fast-curing polyurethane screed that became fully load-bearing within just two days – saving over ten weeks compared to traditional drying times. This quick thinking ensured the project remained on schedule. Additionally, ZETA implemented a flexible, 24/7 work schedule.

Despite pandemic-related travel restrictions and limited site access, ZETA maintained momentum through remote collaboration and digital planning tools. Brexit-related uncertainties around customs procedures were also navigated successfully by applying non-EU export protocols, ensuring timely delivery of all equipment.

ZETA redesigned the cleanroom layout, upgraded HVAC systems, and replaced manual dampers with automated ones. To meet SAPO 4 biosafety requirements, an epoxy bunding system was applied to the cleanroom floor and walls, validated through a successful 2,800-liter flood test. The team also managed all qualification activities, including static and dynamic FATs, a remote software FAT, and a full SAT. Even unique customer requests – such as integrating a vacuum toilet within the cleanroom’s administrative area – were executed with precision, demonstrating ZETA’s commitment to detail and compliance.