Liquid Compounding Capacity Expansion

Confidential Client | Confidential Location

Merrick provided full discipline design services to increase the liquid compounding capacity at two personal care liquids facilities to allow our client to deliver additional volume to market with higher efficiency. The projects included the design and construction of new mixing decks to install a total of five high-throughput mixing units. Our team ensured all design and construction was GMP compliant and executed with minimal disruption to our client’s existing operations, leveraging our expertise with hygienic process design for the unloading, storage, transfer, and compounding of liquid and bulk powder raw materials into finished goods.

The project’s timeline was tight, and the design packages were overlapped with procurement and construction activities. To keep the project on schedule, our team released early work packages to start long lead equipment and building facilities procurement while detailed engineering design was completed. We also sequenced the design work to support meeting the construction timelines for the project. In addition, our team leveraged the lessons learned from the development and design of the first mixing unit to improve subsequent designs.

Our team provided comprehensive design and construction services, including:

  • GMP Facilities Design
  • Hygienic Process Design, including Clean In Place (CIP) Systems
  • HVAC Support for Proper Space Zoning
  • Electrical Power Distribution
  • Controls Integration
  • Construction services
  • Commissioning


FEED Engineering; Detailed Structural Engineering; Detailed Architecture; Hygienic Process Design; Process Piping Design; HVAC; Electrical Power Distribution; Controls Integration; Construction Services; Commissioning; EPCM Project Deliver
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