STERIS Applied Sterilisation Technologies (AST)


Lawler Consulting have been working with STERIS AST over the last 4 years as part of their phased expansion of their facility in the Sragh Industrial Estate, Tullamore. STERIS AST provides contract sterilisation, laboratory testing and product and packaging testing services to manufacturers of medical devices, pharmaceuticals, consumer goods and industrial products.


€15m
Co. Offaly

The phased expansion involved the construction of additional processing capacity through the many sterilisation technologies in use within the facility. Throughout our involvement, we have provided full MEPH services including concept development, design, tender & project management, cost control and process validation related to the MEPH systems.

Phase 1 in 2017 was the new Electron Beam processing facility; In addition to the regular core HVAC & electrical services provision, this facility also required full sprinkler protection, specialist process exhaust, RO water provision, MV site infrastructure upgrade for current and future needs and service provision in highly corrosive atmosphere. All works were integrated back with the existing facility with a high importance put on no downtime to facilitate ongoing Client operations.

In 2018 Phase 2 of the expansion was the introduction of vaporized hydrogen peroxide (VHP) processing capability on site for the first time. This project was of a smaller scale but required more in-depth detailing of MEPH services to equipment supplier’s requirement with an integrated approach from project inception to IOQ sign off.

The Phase 3 project completed in August 2019 was the largest expansion on the site with the addition of a 4000m2 processing warehouse, office accommodation, loading bays and interconnections with the existing facility. In addition to our regular MEPH services, the project included some specialised aspects including;

• 3000kg/hr process steam system
• RO & Soft water systems
• Specialist process pipework systems for ethylene oxide, nitrogen, oxygen & compressed air
• Service provision in ATEX Zones
• Deluge Systems
• Specialist gas detection & alarm systems
• High Temperature Aeration Rooms
• Process exhaust systems
• Site CCTV and access control

The project required in depth collaboration with external and internal equipment and design team members in a live environment with no down time impact on the existing facility.

Phase 4 of the expansion was run concurrently with Phase 3 with the addition of a new 900m2 laboratory facility set over two floors. The new building doubled the size of the existing site laboratory facilities and allowed for an improved process flow and upgraded the overall level of the test areas. In addition to the Class 6 cleanroom, the facility included fume hoods, LAF Units, Autoclaves, Walk In Incubators & industrial scale glasswashers, all requiring a high level of service integration. To provide the facility the Client had ambitiously targeted, we had to gain a good understanding of their day to day processes and future needs. With this collaborative approach we were able to deliver a facility ready for the needs of today but also the changing future requirements in a fast changing industry.

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