Case Study
Turnkey HVAC System Solution for a British Pharmaceutical Research Company
Overview
Client: UK-based global pharmaceutical research organisation
Industry: Pharmaceutical Research and Manufacturing
Project Overview: Newsome delivered a full HVAC solution for a UK-based pharmaceutical research organisation, covering design through to handover, to support precise temperature and air quality control.
When a UK-based global pharmaceutical research organisation required a fully integrated HVAC package to support temperature-sensitive environments, they turned to Newsome for a seamless turnkey solution. The project scope required design, supply, installation, commissioning, and handover of an air handling, dehumidification, and filtration system—This outline showcases how Newsome delivered a high-performance mechanical services installation, from crane delivery of equipment to comprehensive training and documentation.
Project Background and Objectives
The pharmaceutical company operates advanced research facilities which necessitate precise control of temperature, humidity, and airborne contamination. Their intention was to condition a critical process room to 21 °C ±2 °C with maximum 55 percent relative humidity. The system also needed to maintain strict air cleanliness standards while ensuring full compliance with pharmaceutical hygiene criteria. The requirement for packaged heating/cooling, fresh air integration, dehumidification, and HEPA filtration mandated an end-to-end turnkey approach.
System Design and Integration
Newsome’s design engineers meticulously assessed the project specifications and existing equipment. The decision was made to retain some previously installed plant, with Newsome replacing the core HVAC system to meet enhanced environmental standards.
The heart of the solution was an air handling unit (AHU) featuring direct expansion (DX) cooling and integrated heating via heat pump technology. The AHU incorporated an air-to-air heat exchanger, designed for 19,800 m³/hr at 8.5 air changes per hour. Acoustic and hygiene considerations informed the use of insulated, clad galvanised ductwork externally, which transitioned into internally sealed textile air socks for uniform air distribution in the room. Alongside was a dedicated HEPA filtration zone, comprising nine H14-grade Camfil filters within a rigid, sealed housing that incorporated differential pressure measurement via an external magnehelic gauge.
To manage humidity, a stand-alone desiccant wheel unit was positioned beneath the HEPA assembly. Fresh and recirculated air balance, actuated by dampers interlocked with factory-standard controls, achieved stable relative humidity. Controls were integrated via an industrial HMI while interfacing with the client’s SCADA/Modbus architecture.
Logistics and Installation Execution
Coordination of plant delivery required HIAB/crane utilisation due to rooftop placement. Newsome’s project team liaised directly with client facilities to confirm access, health and safety arrangements, and safe handling zones. Externally, the transition point from the delivery vehicle to the rooftop was managed during off-peak hours to reduce disruption. On arriving onsite, Newsome dismantled redundant plant and prepared structural supports. The AHU, HEPA unit, and dehumidifier were craned into position and mechanically secured to vibration-isolated plinths. From there, insulated ductwork was installed, passing through the ceiling void to feed air socks in the process room via discreet, hygienic ceiling diffusers.
Pneumatic and electrical services were terminated at factory-defined proximities. Fresh air dampers were secured in fixed positions to limit makeup air ingress. A single-point power supply was arranged to the AHU’s control panel and the dehumidifier; electrical interfacing then awaited final client-side termination in accordance with modbus protocol.
Commissioning and Functional Performance
Once mechanical installation was complete, Newsome’s commissioning engineers embarked on a phased startup programme governed by client and manufacturer documentation. Initial checks looked for correct airflow, filter integrity, and heater/cooling activation. The second phase focused on dynamic conditions—room load simulation, humidity control, differential pressure measurements, and audio compliance.
At predetermined setpoints of 21 °C and 50 percent RH, control system performance was validated. Multi-point temperature and humidity sensors confirmed the environment remained within specification. As part of the drought of hygroscopic surfaces, air socks were scanned for even airflow during steady-state conditions. High humidity testing validated the cycling of the desiccant wheel, ensuring reliable moisture removal under simulated worst-case loads.
This rigorous approach enabled Newsome to verify custom operating sequences manually, as well as confirm stable Modbus-based BMS interaction. A full system sign-off was completed, giving the green light for training and documentation handover.
Key Project Outcomes
- A modern, filter-controlled HVAC system delivering consistent temperature and humidity throughout operational hours.
- Integration with client SCADA enables remote monitoring and alerts, reducing the need for manual checking.
- The combination of AHU, HEPA, and desiccant systems maintains 21 °C and 50 percent RH, whilst meeting GMP-grade air cleanliness.
- Comprehensive documentation and training ensures effective operation and ease of handover to onsite engineers.
- System designed for accessibility and maintainability, with provision for ventilator and filter swaps without compromising cleanliness.
Commissioning and Functional Performance
Once mechanical installation was complete, Newsome’s commissioning engineers embarked on a phased startup programme governed by client and manufacturer documentation. Initial checks looked for correct airflow, filter integrity, and heater/cooling activation. The second phase focused on dynamic conditions—room load simulation, humidity control, differential pressure measurements, and audio compliance.
At predetermined setpoints of 21 °C and 50 percent RH, control system performance was validated. Multi-point temperature and humidity sensors confirmed the environment remained within specification. As part of the drought of hygroscopic surfaces, air socks were scanned for even airflow during steady-state conditions. High humidity testing validated the cycling of the desiccant wheel, ensuring reliable moisture removal under simulated worst-case loads.
This rigorous approach enabled Newsome to verify custom operating sequences manually, as well as confirm stable Modbus-based BMS interaction. A full system sign-off was completed, giving the green light for training and documentation handover.
Client Training, Manuals, and Operational Support
Prior to handover, Newsome’s engineers led operator training sessions covering control interface operation, maintenance routines, and safety precautions. Manuals were compiled to include thorough record drawings, equipment data plates, operational graphs, and step-by-step maintenance guidelines emphasising filter replacement, desiccant wheel regeneration, and BMS alarm response.
By maintaining clear documentation of existing retained plant and the newly installed system, clients gained understanding of integration points, renewal strategies, and servicing requirements. Newsome’s team also ensured that onsite staff members were fully confident in basic diagnostics, escalation processes, and safe isolation procedures.
Efficiency, Compliance and Long-Term Benefits
Deploying this turnkey solution has delivered greater process stability, reduced contamination risk, and improved energy performance compared to legacy systems. The use of insulated ductwork and precision–balanced airflow has minimised thermal losses and restrained energy consumption. Fixed fresh air dampers and recirculation features maintain air quality while controlling humidity.
The design allows the site to operate continuously, maintaining 8.5 air changes per hour around the clock with minimal fresh air intake—reducing heating/cooling demand. The HEPA filters and robust dehumidification strategy bolster compliance with pharmaceutical-grade hygiene, while Newsome’s control scheme ensures early alarm detection for filtration breach or humidity drift.
Conclusion
The successful delivery of this turnkey HVAC scheme highlights Newsome’s ability to execute multidisciplinary projects for technically demanding environments. By combining engineering rigour, methodical installation, and rigorous commissioning with bespoke controls and robust client training, Newsome delivered a solution that supports performance, compliance, and operational resilience.
Through attention to detail—such as vibration isolation, filter integrity, and control integration—Newsome not only replaced outdated plant but elevated the facility’s environmental stability, enhancing confidence in ongoing research operations. The project reaffirms Newsome’s reputation as a trusted partner for delivering complex mechanical services solutions within the pharmaceutical sector.
If your facility requires precision HVAC in controlled environments, contact Newsome today to explore how turnkey design, installation, and commissioning can support your operational goals.