HVAC Upgrade for GlaxoSmithKline Blow Fill Seal Facility

The HVAC system upgrades were delivered with minimal production downtime, while creating significant improvements to the energy efficiency, maintenance accessibility, room pressure and condition stability, and to allow for the future expansion of mechanical systems.


  • Australia


  • Shortlisted for 2016 AIRAH Awards in the Best HVAC&R Retrofit or Upgrade Award category

GlaxoSmithKline Blow Fill Seal Facility HVAC Upgrade included major air handling units within a live manufacturing environment, serving production critical areas within the GlaxoSmithKline Boronia site, including GMP Grade C Blow Fill Seal Filling Suites, as well as Manufacturing Rooms and general support areas.


The project delivery was a very fast-track program and further challenged by significant existing site constraints. To keep all existing pharmaceutical manufacturing processes uninterrupted, which would otherwise have resulted in significant loss of production costs, a new roof top plant room was built to accommodate the new mechanical plant, including an air handling plant and central boiler plant.


All new works were designed and planned to be undertaken while keeping all existing services fully operational. The majority of commissioning tasks on the new systems were completed prior to cut-over. The cut-over process, including final ductwork connections, air balancing, final commissioning, automatic controls tuning and verification, had to be completed over a three-day period during GSK plant shutdown, and required a high degree of planning.