Our Partnership with Geltech

Building a Fully Integrated, GMP-Compliant Manufacturing Environment from the Ground Up

Client Overview

Geltech is an emerging pharmaceutical manufacturer focused on delivering high-quality soft gel capsules and tablet formulations. With increasing demand for nutraceutical and pharmaceutical products, the company sought to establish a world-class, turnkey manufacturing facility capable of meeting stringent GMP, environmental, and operational standards.

They needed a partner who could deliver end-to-end solutions, from consultancy and design to installation and commissioning, while ensuring seamless integration of all cleanroom, HVAC, utility, flooring, electrical, and automation systems.

They chose us.

The Challenge

This project required more than building a standard pharmaceutical facility. It demanded strict compliance, precise coordination, and full-scale engineering across multiple disciplines. Key challenges included:

• Creating controlled cleanroom zonessuitable for soft gel and tablet production
• Integrating complex HVAC systems to maintain temperature, humidity, and particulate requirements
• Coordinating utility-heavy areas such as steam generation, purified water systems, and electrical distribution
• Implementing automation and monitoring systems (BMS/EMS) capable of real-time control
• Ensuring flawless execution across civil, MEP, and process-related installations
• Designing a facility that supports future expansion while maintaining strict GMP workflows

The mission was clear:
Build a turnkey pharmaceutical manufacturing facility that meets global regulatory standards from day one.

Our Approach: Engineering a Complete Turnkey Solution

We deployed a cross-functional team of cleanroom specialists, HVAC engineers, automation experts, utility designers, and project managers. Our strategy combined holistic planning, rigorous engineering, and compliance-aligned execution.

Cleanroom Partitions: Creating Controlled Environments for Precision Manufacturing

To support soft gel and tablet manufacturing, we designed and installed:

• GMP-compliant cleanroom partitions
• Seamless, sterility-focused wall systems
• Controlled-access doors optimized for pressure stability
• Zoning layouts that differentiate processing, encapsulation, drying, coating, compression, and packing.

These sterile environments became the backbone of Geltech’s controlled production workflow.

High-Side & Low-Side HVAC: Engineering the Right Air Quality, Always

We implemented a complete HVAC ecosystem engineered specifically for pharmaceutical production, including:

• High-side HVAC with AHUs, filtration stages, and treated air systems
• Low-side HVAC with FCUs, ducting, and pressure-balancing mechanisms
• Temperature and humidity control optimized for soft gel production
• Cleanroom-classified air quality with HEPA filtration
• Room pressure cascades for cross-contamination prevention

The system ensures consistent, reliable environmental conditions essential for manufacturing integrity.

BMS & EMS Integration: Intelligent Control at Every Step

For enhanced efficiency and oversight, we integrated:

• Building Management System (BMS):
  Monitors and controls HVAC, pressure differentials, temperature, humidity, and ventilation.
• Energy Management System (EMS):
  Tracks and optimizes energy usage to improve sustainability and reduce operating costs.

This automation framework gives Geltech complete visibility and control over its facility’s performance.

Electrical Works: Powering a High-Performance Facility

We delivered a robust pharmaceutical-grade electrical infrastructure that included:

• Complete power distribution systems
• Cleanroom-compatible lighting solutions
• Emergency and backup power integration
• Panels, cabling, earthing, and safety systems
• Electrical provisions for specialized production and processing equipment

Every installation was executed to support reliability, safety, and uninterrupted operations.

Flooring Works: Hygienic, Durable & Cleanroom-Ready

We supplied and installed:

• Seamless epoxy flooring with covingto eliminate contamination traps
• Chemical-resistant surfaces suitable for production, processing, and washing areas
• High-durability flooring engineered to withstand heavy machinery and foot traffic

The flooring design enhances GMP hygiene and long-term facility resilience.

Boiler System: Steam When and Where It’s Needed

We designed and installed a central boiler system to supply steam for:

• Sterilization
• Capsule processing
• Equipment cleaning
• Utility support functions

The system ensures consistent steam supply with safety and regulatory compliance.

Water Generation System: Pure Water for Critical Processes

We implemented a pharmaceutical-grade water system that included:

• Water generation and purification
• Storage and distribution
• Quality monitoring
• Delivery points for both production and laboratory use

The system ensures reliable access to purified water essential for soft gel and tablet formulation.

The Result: A Fully Integrated, GMP-Ready Manufacturing Facility

The completed facility now delivers:

• Seamless cleanroom environments for soft gel and tablet production
• Stable HVAC-controlled conditions supporting precision manufacturing
• BMS and EMS automation for real-time monitoring
• Reliable electrical, flooring, steam, and purified water systems
• A turnkey design that enhances efficiency, compliance, and scalability

Geltech now operates a high-performance facility built for current needs and future growth.

Key Achievements

• Delivered a complete turnkey soft gel & tablet manufacturing facility
• Installed integrated cleanroom, HVAC, utility, and automation systems
• Engineered GMP-compliant controlled environments
• Designed for scalability, operational efficiency, and workflow optimization
• Executed complete installation and commissioning under a unified project framework

What This Project Says About Us

This project demonstrates our ability to:

• Deliver complex pharmaceutical facilities from concept to commissioning
• Integrate multidisciplinary systems into a single, unified turnkey solution
• Engineer highly regulated production environments with precision
• Support emerging manufacturers in scaling to global standards

Conclusion

The Geltech turnkey facility stands as a powerful example of what expert engineering, detailed planning, and flawless execution can achieve.
Every system, from cleanrooms and HVAC to utilities, flooring, and automation, was built to support safe, efficient, and compliant pharmaceutical manufacturing.

We don’t just create turnkey facilities.
We build environments where pharmaceutical innovation thrives.