Fresenius Kabi USA, LLC, (FK) is a supplier of multi-source injectable pharmaceutical products. Their Grand Island, NY site is a 22.5-acre facility generally comprised of office, manufacturing, and warehousing buildings (approximately 340,000 sf under roof), with an active wastewater treatment facility (WWTF).
Fresenius Kabi has determined that an expansion of the WWTF in the form of redundant treatment operations is needed to accommodate anticipated increases in flow from new production operations and projected future growth; allow for maintenance shutdown; and provide backup in the event of a treatment process upset. FK turned to Wendel to design and help building a parallel plant that will double their capacity. This additional capacity provides redundancy and enables the manufacturing process to continue even during routine maintenance of the WWTF.
The expedited design included a new continuous flow Sequencing Batch Reactor treatment process, new influent pumping station, a new plant-wide SCADA system, and miscellaneous mechanical, structural and architectural modifications. Availability of land, location of existing critical utilities, and the necessity to maintain 24/7 operation all played a prominent role in the design of the new facilities, as well as the sequencing of construction. Construction has been completed and the system is in operation.