Pharmaceutical Manufacturing

WalterFedy’s long-term relationship with McNeil Consumer Healthcare (a member of the Johnson & Johnson Pharmaceutical family of companies) began in 1982 with the addition of a new Tylenol manufacturing facility to the original office. Our firm has since provided full-service architectural and engineering consulting services for all additions to the company’s original plant, including new manufacturing capacity, compression rooms, coating rooms, packaging and warehouse facilities, expansion to the liquid Tylenol manufacturing area, and a new narcotics vault. 

In 1998, we added 10,000 sq.ft. of office and staff facilities, incorporating the new space into the overall site by using existing pre-cast from the original building. In 2001, we provided design services for the new coating pan addition and loading-dock expansion.

The following year, we provided engineering services for three additions to their existing facility: a loading dock and staging area, a process and mechanical space, and a process-materials storage area. All work was accomplished in a clean environment according to pharmaceutical industry requirements. Our team also provided site services to re-route a water main, move a road, and extend an existing parking lot.

In 2003, our team re-constructed McNeil’s existing main and rear vehicular entrances, expanded the parking lot, upgraded the electrical service and air conditioning in the warehouse, and assisted in re-roofing portions of the existing, twenty-year-old roof systems.

Our most recent work, carried out in 2010, involves the renovation of an existing office into a clean, pharmaceutical-process quality-control lab consisting of a 2,100 sq.ft. laboratory and a 1,200 sq.ft. clean room for the archiving of processed samples. While the project parameters were well-defined by McNeil’s facilities staff, we met with the lab director to identify program requirements, which included both new equipment and the relocation of existing equipment from another lab.

The lab is designed to ISO 14644-1 Class 8, and includes three rooms that are zoned and pressurized with air locks (featuring interlocked, sliding glass doors with card-access control), two autoclaves with fume hoods, three biosafety cabinets, eight large incubators, and proprietary lab testing equipment. The controlled air supply employs a differential-pressure system with 30 air changes per hour (filtered to HEPA 99.97% at 0.3 microns).

As McNeil manufactures Tylenol products, all components of our work over the years have involved a high degree of complexity to incorporate building systems specific to the pharmaceutical industry and Good Manufacturing Practices (GMP).