Pharmaceutical Water & Clean Steam Systems – Bayer Animal Health (NZ)
Client: Bayer Animal Health / AB Mandal
Location: Auckland, New Zealand
Project Scope: Purified Water (PFW), Water for Injection (WFI), and Clean Steam Systems
Completion: 2016
Sector: Pharmaceutical Manufacturing
Bayer Animal Health required a new pharmaceutical-grade water generation and distribution system at its Manukau facility in Auckland, New Zealand. The project included both Purified Water (PFW) and Water for Injection (WFI) plants, as well as a Clean Steam generation and distribution system to support GMP-compliant production processes.
The challenge was to design and deliver an integrated system capable of meeting stringent quality standards while ensuring reliability, scalability, and seamless operation within Bayer’s production environment.
Umech’s Role
Umech provided a turnkey design-and-construct solution, including:
Hydraulic sizing calculations for PFW and WFI distribution loops
Process modelling to determine tank storage and generation system capacities
System integration and import of major equipment including:
Water purification systems
WFI Still
Clean Steam generator
Storage vessels
3D design and prefabrication of process skids in Umech’s Sydney fabrication facility
SCADA/PLC control system design, including:
Hardware and software design specifications
Electrical drawings
Factory Acceptance Testing (FAT) of the main control panel
Onsite installation in Auckland of both mechanical piping and electrical/controls
Commissioning and Site Acceptance Testing (SAT) of the plants
Delivery of operation and maintenance manuals
Provision of ongoing maintenance support to Bayer
Technical Highlights
Fabrication of skid-mounted process units in Sydney while concurrently running an onsite team of welders for efficient project delivery
Integration of water purification, WFI, and Clean Steam systems to GMP standards
SCADA-controlled automation with PLC-based monitoring for reliability and traceability
Site construction management and quality assurance throughout installation
Full FAT and SAT testing ensuring compliance and performance prior to handover
Outcome
The new water and steam plant provided Bayer with a fully compliant, reliable, and validated pharmaceutical water and steam system. The infrastructure enabled continuous operation under GMP conditions, ensuring Bayer could meet global quality standards for its animal health products.
Umech’s ability to integrate mechanical, electrical, and control systems, combined with prefabrication and onsite delivery, ensured a seamless handover and long-term maintainability. Umech continues to provide this facility with on going maintenance and support.
Need pharmaceutical-grade water or steam systems for your facility?
Umech delivers GMP-compliant PFW, WFI, and Clean Steam plants with prefabricated skids, automation, and full commissioning services. Talk to our engineering team about your next project.