AQI-D3 β Full Build Master Plan
190,780 sq ft built-up (35.00 kanals). Largest production and packing envelope, 77,680 sq ft production hall, 2,808-pallet finish goods store.
A complete turnkey engineering proposal for a greenfield sterile large-volume and small-volume parenteral manufacturing campus β architectural master planning, ISBM/blow-fill-seal process line, clean utilities, cleanroom HVAC and full regulatory validation delivery.
Both design options are developed on the same 195,050 sq ft useable plot with an identical utility block, raw material store and QC/admin core. They differ in production train configuration and warehouse strategy. All figures below are taken directly from the issued master plan drawings dated 07-08-2026 β no values are estimated.
190,780 sq ft built-up (35.00 kanals). Largest production and packing envelope, 77,680 sq ft production hall, 2,808-pallet finish goods store.
138,335 sq ft built-up (25.40 kanals). Compact 36,275 sq ft production core with the highest storage density β 3,564 pallet slots.
| Functional Block | AQI-D3 Β· sq ft | AQI-D3 Β· kanals | AQI-D4 Β· sq ft | AQI-D4 Β· kanals |
|---|---|---|---|---|
| Production Area | 77,680 | 14.26 | 36,275 | 6.66 |
| Packing Hall | 21,400 | 3.93 | 10,000 | 1.83 |
| Finish Goods Store | 52,420 | 9.62 | 52,780 | 9.69 |
| Raw Material Store | 6,650 | 1.22 | 6,650 | 1.22 |
| Reserved Raw Material Store | 20,350 | 3.73 | 20,350 | 3.73 |
| Utility Block | 6,460 | 1.18 | 6,460 | 1.18 |
| Q.C, Admin & Production Entrance | 5,820 | 1.06 | 5,820 | 1.06 |
| Total Built-Up Area | 190,780 | 35.00 | 138,335 | 25.40 |
Useable plot area for both options = 195,050 sq ft. Area statement is stated per the drawings as βfor one lineβ. Finish goods storage capacity: AQI-D3 = 2,808 pallets Β· AQI-D4 = 3,564 pallets Β· reserved raw material store 1,188 pallets plus a 288-pallet zone.
Drag to orbit, scroll to zoom. Switch between both master plan options, jump to camera presets and toggle model layers. Cleanroom floors are colour-coded by GMP classification.
Ten drawing sheets across architectural, process machinery and clean utilities disciplines, rendered at high resolution from the issued CAD set. Click any sheet to open the full-size vector-derived view; native DWG and PDF files are in the download register below.
Full dual-train campus master plan. 190,780 sq ft built-up on a 195,050 sq ft useable plot, 2,808-pallet finish goods store.
Compact high-bay phased variant. 138,335 sq ft built-up, 3,564-pallet high-bay finish goods store.
Injection-stretch-blow-moulding and filling line general arrangement, drawing M-F26002.
23-station packing line: 105 crescent slat conveyor, labeller β₯400 bph, JDZ-320P cartoners, case packing and coding.
Automatic visual inspection machine with re-inspection function and two electrical cabinets; external dimensions.
Water-bath terminal steriliser room, 38,760 Γ 12,500 mm envelope, sterilisation carts, report printer and monitoring PC.
Mixing tanks, API tank, vacuum system, 3 m pipe-support platform and electrical cabinet. Room height β₯ 6 m.
15-item water train: multi-media filter, softener, activated carbon, pH dosing, RO, PW tank, multi-effect distiller, WFI tank, CIP.
Horizontal water-for-injection storage vessel, 10 tonne capacity.
Horizontal water-for-injection storage vessel, 20 tonne capacity.
Indicative design visualisations of the principal process suites, clean utilities and logistics areas, annotated with the equipment ratings and dimensions taken from the issued drawing set. Click any image to enlarge.
Blow-fill-seal aseptic filling and sealing under Grade B conditions with terminal HEPA filtration.
PG15T3 + PG15T3 mixing vessels, API tank and vacuum system on a 3 m pipe-support platform. Clear height β₯ 6 m.
Water-bath terminal steriliser with loading carts, report printer and monitoring PC. Room envelope 38,760 Γ 12,500 mm.
Automatic optical inspection with re-inspection function, reject collection and two electrical cabinets.
105 crescent slat conveyor, labeller β₯ 400 bph, JDZ-320P cartoners, case erector, sealer and checkweigher.
Multi-effect distiller, RO skid, filtration train, WFI storage 10 T / 20 T and sanitary distribution loop.
Interlocked airlock with differential pressure monitoring, staged gowning benches and hand-wash station.
Selective pallet racking β 3,564 pallet slots in the AQI-D4 high-bay option, 2,808 in AQI-D3.
Four hydraulic dock levellers with shelters and semi-trailer access. Dock platform height 8'-9".
Note: the images above are design visualisations produced to communicate intent and scale. They are not photographs of the proposed plant and are not construction documents β refer to the issued drawing register for dimensional information.
Room names and corridor classifications are transcribed from the issued master plan drawings. Corridors are 2,500 mm wide throughout and graded Class B, C and D.
Seven engineering divisions. Quantities marked TBC are to be confirmed at detailed design stage and are deliberately not estimated here.
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 1.1 | Excavation, filling & sub-structure works for 195,050 sq ft useable plot | LS | TBC | Foundations for 2-storey frame + truck dock platform at 8 ft 9 in |
| 1.2 | Reinforced concrete 2-storey frame with slab at +6.0 m | mΒ³ | TBC | Manufacturing/compounding room clear height β₯ 6 m; water system room β₯ 4.5 m |
| 1.3 | Prestressed precast double-tee concrete roof system | mΒ² | TBC | Double-tee spanning; superstructure roofing over production block |
| 1.4 | Compounding pipe-support platform (steel, 3 m height) | EA | TBC | Supports PG15T3+PG15T3 compounding/mixing system |
| 1.5 | Truck dock platform (height 8 ft 9 in) | EA | TBC | Loading/unloading interface |
| 1.6 | Variant AQI-D3 β total built area 190,780 sq ft (35.00 kanals) | mΒ² | TBC | Production 77,680; Packing Hall 21,400; Finish Goods 52,420; RM Store 6,650; Reserved RM 20,350; Utility 6,460; QC/Admin 5,820 |
| 1.7 | Variant AQI-D4 β total built area 138,335 sq ft (25.40 kanals) | mΒ² | TBC | Production 36,275; Packing Hall 10,000; Finish Goods 52,780; RM Store 6,650; Reserved RM 20,350; Utility 6,460; QC/Admin 5,820 |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 2.1 | GMP cleanroom envelope β Classes B, C and D | mΒ² | TBC | Segregated grades per process flow |
| 2.2 | Modular cleanroom wall & ceiling panels (Class B/C/D rooms) | mΒ² | TBC | Named rooms: Injection Molding & Blowing, Filling & Sealing, Compounding, Dispensing (2 booths), Dispensed Material Storage, Granules Feeding, Autoclave Loading, Cooling Zone, Terminal Sterilization, Centralized Sterilization Monitoring, IPQC, PPM Material Day Stock, Washing/Laundry, Sampling Area & Booth, Material Receiving, Material Dispatch, De-Dusting Airlock-1/-2, Material Airlock, Raw Material Airlock, CR-1 to CR-4, Airlock-1/-2 |
| 2.3 | Cleanroom doors & interlocked airlock doorsets | EA | TBC | Includes De-Dusting Airlocks, Material Airlocks, Change Rooms CR-1 to CR-4 |
| 2.4 | Cleanroom grade epoxy / vinyl flooring | mΒ² | TBC | Seamless, coved, cleanable finish |
| 2.5 | Corridors (2500 mm wide) cleanroom construction | m | TBC | Main personnel & material circulation spine |
| 2.6 | Support & administrative spaces (offices, visitor corridor, drivers waiting, battery charging, tool room, workshop, janitorial) | mΒ² | TBC | Manager Office, Engineer Office, Offices 1-2, Future Extension for Offices |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 3.1 | Injection-Stretch-Blow-Moulding / Blow-Fill-Seal all-in-one line | EA | TBC | Integrated ISBM-BFS monobloc |
| 3.2 | Automatic visual inspection machine (VIM), rated 24,000 BPH with re-inspection | EA | 1 | Includes 2 electric cabinets |
| 3.3 | Manual visual inspection station | EA | TBC | Back-up / secondary inspection |
| 3.4 | Water-bath terminal sterilizer (autoclave) with sterilisation report printer & monitoring PC | EA | TBC | Room envelope 38,760 mm Γ 12,500 mm; 2500/1500 mm clearances; sterilisation carts |
| 3.5 | Compounding/mixing system 'PG15T3+PG15T3' | EA | TBC | Mixing tank, API tank, vacuum system, pipe-support platform, electrical cabinet |
| 3.6 | 105 crescent slat conveyor with SEW motors | EA | TBC | Packing-line transport |
| 3.7 | Automatic labelling machine (tertiary inspection + white-bottle inspection + rejection) | EA | TBC | Speed β₯ 400 bottles/min |
| 3.8 | Pillow packing machine (100 ml) | EA | TBC | Speed β₯ 200 bottles/min |
| 3.9 | Cartoning machine (100 ml) | EA | TBC | Speed β₯ 200 bottles/min |
| 3.10 | JDZ-320P high-speed cartoners (twin-rotary-disc feed) | EA | 2 | 2 off as verified on vendor drawing |
| 3.11 | Pillow-bag case packer (3 cartons per loading) | EA | TBC | Speed β₯ 400 bottles/min |
| 3.12 | Carton case packer (3 cartons per loading) | EA | TBC | Speed β₯ 400 bottles/min |
| 3.13 | Case erector | EA | TBC | Speed β₯ 13 cartons/min |
| 3.14 | Carton erector with pad placement | EA | TBC | β |
| 3.15 | Checkweigher | EA | TBC | In-line weight verification |
| 3.16 | Leaflet & certificate feeder | EA | TBC | β |
| 3.17 | Case sealer | EA | TBC | β |
| 3.18 | Corner labeler | EA | TBC | β |
| 3.19 | Case date & lot printing with inspection | EA | TBC | Coding + vision inspection |
| 3.20 | Pillow-pack 3-jaw fixtures for 100 / 250 / 500 / 1000 ml | SET | TBC | 4 size fixtures per line |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 4.1 | Raw water tank | EA | TBC | Feed to pre-treatment |
| 4.2 | Raw water pump | EA | TBC | β |
| 4.3 | Plate-type heat exchanger | EA | TBC | β |
| 4.4 | Multi-media filter | EA | TBC | β |
| 4.5 | Softener | EA | TBC | With brine tank |
| 4.6 | Brine tank | EA | TBC | Regeneration media |
| 4.7 | Activated carbon filter | EA | TBC | β |
| 4.8 | pH dosing device | EA | TBC | β |
| 4.9 | RO unit | EA | TBC | Pre-purification |
| 4.10 | PW tank | EA | TBC | Purified Water storage |
| 4.11 | PW/WFI distribution module | EA | TBC | Loop & distribution skid |
| 4.12 | Multi-effect water distiller | EA | TBC | WFI generation |
| 4.13 | WFI tank | EA | TBC | WFI storage |
| 4.14 | Horizontal WFI storage tanks (10 T and 20 T) | EA | TBC | Dual-capacity tanks per vendor list |
| 4.15 | CIP tank | EA | TBC | β |
| 4.16 | CIP pump | EA | TBC | β |
| 4.17 | Utility tie-ins β raw water inlet DN50 @ 2-4 bar | EA | TBC | Site connection |
| 4.18 | Utility tie-ins β cooling water 2-4 bar @ 7-12 Β°C; industrial steam 3-8 bar; condensate separate discharge | EA | TBC | Utility room services |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 5.1 | HVAC air-handling units for GMP Classes B, C and D | EA | TBC | Grade-specific air change rates |
| 5.2 | HEPA/ULPA terminal filtration & containment | EA | TBC | Class B critical zones |
| 5.3 | Compressed air supply DN15 @ 6-8 bar to each solenoid valve box | EA | TBC | Per equipment box tie-in |
| 5.4 | Building Management System (BMS) & monitoring | LS | TBC | Environmental & utility monitoring |
| 5.5 | Room temperature control (utility room below 30 Β°C) | EA | TBC | Environmental specification |
| 5.6 | Drainage trench W300 Γ H300 with DN100 floor drains | m | TBC | Process & utility drainage; condensate separately discharged |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 6.1 | Electrical substation & LV incoming | LS | TBC | Site power intake |
| 6.2 | LT distribution boards & cabling | LS | TBC | Building-wide power |
| 6.3 | Power supply 380 V / 50 Hz three-phase five-wire to each control cabinet | EA | TBC | Per vendor equipment requirement |
| 6.4 | Emergency power β generator & automatic transfer | EA | TBC | Critical & life-safety loads |
| 6.5 | UPS & emergency lighting | LS | TBC | Cleanroom & BMS continuity |
| Item No. | Description | Unit | Qty | Remarks |
|---|---|---|---|---|
| 7.1 | Finish Goods Store racking β Variant AQI-D3 (2,808 pallets) | PALLET | 2808 | 52,420 sq ft store; pallet positions per verified layout |
| 7.2 | Finish Goods Store racking β Variant AQI-D4 (3,564 pallets) | PALLET | 3564 | 52,780 sq ft store; pallet positions per verified layout |
| 7.3 | Raw Material Store racking (6,650 sq ft) | PALLET | TBC | β |
| 7.4 | Reserved Raw Material Store racking (20,350 sq ft) | PALLET | 1188 | Plus a 288-pallet area; 1,188 pallets per verified layout |
| 7.5 | Reserved RM Store additional pallet area (288 pallets) | PALLET | 288 | Separate area within reserved RM store |
| 7.6 | Material handling equipment (forklift, pallet trucks, battery charging) | EA | TBC | Battery charging room provided |
Click any package to open its deliverable schedule and governing references.
Establish the legal manufacturing authorisation and site documentation baseline with DRAP.
Governing references: DRAP Act & Rules; DRAP Good Manufacturing Practices; Site Master File format.
Align facility design and operations to WHO Good Manufacturing Practices (TRS 961).
Governing references: WHO TRS 961 (Good Manufacturing Practices for pharmaceutical products).
Implement PIC/S sterile-manufacture requirements for LVP/SVP IV solutions.
Governing references: PIC/S PE 009-17 Annex 1 (Manufacture of Sterile Medicinal Products).
Design personnel gowning and flow controls to EU GMP Annex 1.
Governing references: EU GMP Annex 1 (Manufacture of Sterile Medicinal Products); PIC/S PE 009-17 Annex 1.
Author the site Validation Master Plan governing all qualification and validation.
Governing references: WHO TRS 961; EU GMP Annex 1; PIC/S PE 009-17 Annex 1; ISO 14644.
Develop the Contamination Control Strategy for sterile LVP/SVP manufacture.
Governing references: EU GMP Annex 1; PIC/S PE 009-17 Annex 1; ISO 14644.
Execute design through performance qualification for facilities, utilities and equipment.
Governing references: WHO TRS 961; EU GMP Annex 1; PIC/S PE 009-17 Annex 1; ISO 14644.
Validate Purified Water and WFI generation, storage and distribution in three phases.
Governing references: WHO TRS 961; EU GMP Annex 1; PIC/S PE 009-17 Annex 1.
Qualify HVAC and classify cleanrooms to ISO 14644 for Grades B, C and D.
Governing references: ISO 14644; EU GMP Annex 1; PIC/S PE 009-17 Annex 1; WHO TRS 961.
Validate the water-bath terminal sterilizer and define qualified load patterns.
Governing references: EU GMP Annex 1; PIC/S PE 009-17 Annex 1; WHO TRS 961.
Validate GMP computerised systems and assure data integrity to ALCOA+.
Governing references: ALCOA+ data integrity principles; EU GMP Annex 1; PIC/S PE 009-17 Annex 1; WHO TRS 961.
Deliver as-built documentation and operation & maintenance dossier at handover.
Governing references: WHO TRS 961; EU GMP Annex 1; PIC/S PE 009-17 Annex 1; ISO 14644.
Utility tie-in parameters and structural criteria as stated on the issued vendor and architectural drawings.
Original issued files β native AutoCAD DWG and vector PDF, exactly as received from the design and vendor teams.