Reference projects

Below you can find a selection of reference projects that give you an impression of our expertise.

Pharmaceuticals reference projects
Gerresheimer
Allergopharma
WDT
Excella (Fareva Group)

Gerresheimer

Gerresheimer is a leading global partner in the pharmaceutical and healthcare industry, with a workforce of approx. 10,000 worldwide – wherever their customers and markets are. The product range includes pharmaceutical packaging and products for the simple and secure administration of drugs.

Cooperation

Gerresheimer has been a valued customer for many years. In 2001 we supplied their site in Bünde with PW, HPW and WFI generating systems designed specifically for their facilities, along with the associated storage and distribution systems. Gerresheimer uses an automated loop system to distribute brine to all of its softening units.

Future-oriented projects

Since 2019 we have also been involved at the Regensburg site, where we installed a system for generating PW and another for WFI, encompassing WFI generation, storage and distribution, all with our hallmark quality. Our cooperation produces turnkey systems with qualification and documentation that meet the requirements of the pharmaceutical industry, for structured and qualified project implementation.

Allergopharma (formerly MERCK Group, now Dermapharm Holding)

Allergopharma specialises in subcutaneous immunotherapy (SCIT) and is a market leader in this field in Germany. The company offers a wide range of high-dosage, hypoallergenic preparations, known as allergoids for SCIT. Its portfolio also encompasses a wide range of allergens for diagnostics.

Tendering criteria

When it put its pure media systems for its new production facility out to tender, Allergopharma was looking for systems from a single source, including a new pure steam generator, a new WFI generator and storage unit, and a new AP generator and storage unit including a uniform system and control concept.

Implementation

During the tender and award phase, the technical support department responsible for process systems, pure media supply, ventilation technology, building control technology and for organising maintenance and calibrations, all under the management of Mr Meinke, was presented with a holistic concept and introduced to the project team responsible for implementation. Units we had already installed in other projects and their automation systems were what ultimately persuaded Allergopharma to opt for our solution. Other reasons for the collaboration were that, alongside construction and automation, commissioning and qualification were all provided by one and the same supplier, meaning that the systems could be delivered, set up and running on schedule.

WDT

The Cooperative of German Veterinarians (WDT) is a leading player in the German veterinary market, with a presence in over 95% of all German veterinary surgeries. With a proud company history stretching back over 114 years, the 280 WDT employees manufacture primary care products for veterinary surgeries.

Tender

Back in 2002, our PW and PS generation and distribution systems at the Garbsen site made an excellent impression. A particular challenge we faced at this site was the small footprint for the installation, which demanded a customised system design. The customised PW generation, storage and distribution system as well as a combi-system for simultaneous generation of pure steam and WFI with the associated storage and distribution, with an optimised process, were supplied right on schedule.

Growth

The increased production capacity that accompanied the growth of the company meant that the water treatment systems needed to be adjusted accordingly. WDT opted for tried and tested quality. Now more than 7100 owners of veterinary surgeries benefit from the high quality of WDT’s own preparations and products.

Referenzanlage für Wirtschaftsgenossenschaft Deutscher Tierärzte

Excella (Fareva Group)

The 400-strong workforce at Excella GmbH & Co. KG (formerly Heumann PCS GmbH) produce active pharmaceutical ingredients and finished pharmaceutical products as contract manufacturers. To be able to compete in the pharmaceutical industry, it is important to offer consistently high quality at competitive prices.

“Over the past few years, the active pharmaceutical ingredients business has seen a trend towards ever smaller quantities and ever more potent substances”, explains Klaus Eichelsdörfer from Excella GmbH.

Project requirements

In the tenders for the pure media systems for various new production areas, as well as replacement investments, Excella GmbH & Co. KG placed an emphasis on obtaining all new acquisitions and reinvestments for pharmaceutical water production from a single source. Over the last few years, this has included two new HPW generator systems, each connected to a storage and distribution system, a new PW generator system with its own storage and distribution system for QC, and in 2021 a new PW generator system with the associated storage and distribution system as a replacement investment.

Implementation

In the tender and award phase, we presented a holistic concept and introduced the project leader who would be responsible for the implementation to the department responsible for technical support for process systems and pure media supply . Excella was impressed to find that the existing systems and units from Wilhelm Werner GmbH, as we were called at the time, and the associated automation systems, met all of the points on their checklist. Other reasons for opting to collaborate with us were that, alongside construction, manufacture, and automation, both commissioning and qualification were provided by one and the same supplier.

Anlage vom Referenzprojekt mit Excella (Fareva GroupÄ)

High Purity reference projects
SiCrystal
Siemens Energy Global

SiCrystal

SiCrystal is a global market leader in single crystalline silicon carbide (SiC) wafers. The highly specialised products are the basis for the production of innovative electronic components for key customers across the globe. Silicon carbide (SiC) wafers are high-precision disks that are typically just 350 micrometres (about 1/3 mm) thick and 150 mm in diameter. These wafers have to meet extremely stringent specifications stipulated by the customer and require highly sophisticated manufacturing equipment.

Project requirements

In 2011, SiCrystal GmbH was looking for an ultrapure water unit to supply the wet processes in their planned production plant in Nuremberg. The layout of the ultrapure water unit and the specification of the parameters to be observed were implemented in close cooperation with the engineering office commissioned with planning, the users in the wet process division at SiCrystal GmbH and Wilhelm Werner GmbH. In addition to general criteria such as the specific resistance of 18.2 MΩxcm, it was particularly important to achieve single-digit anion and cation ppt values (< 0.005 µg/l).

Implementation

Together with the team, the required volumes were also specified to supply 3 subloops. The ultrapure water unit consists of a make-up process with a production output of 4 m³/h comprising a water softening unit, a reverse osmosis unit, and a CEDI system. The DI water generated by this system is supplied to a buffer tank with an effective volume of 20 m³ and a conductivity of < 0.2 µS/cm. To prevent recontamination of the ultrapure water, the tank was made of pure polypropylene and shielded from the atmosphere with a sterile filter and CO2 absorber. The DI water is fed to the polishing system by two redundant loop pumps and passed through two parallel UV oxidation systems to the polishing system, where the final polishing is carried out by two ultrapure resin cartridges connected in series. The ultrapure water then passes into the three loops through a 0.20 µm filter at a rate of 9 m³/h.

Siemens Energy Global

Siemens Energy Global is an established manufacturer and operator of hydrogen electrolysis systems. As a future energy source, the various applications of hydrogen include environmentally friendly fuel for fuel cell vehicles and industrial facilities and use as a raw material in the chemical and pharmaceutical industries. Hydrogen can also be fed into the natural gas network, where it can be used for heating and electricity. Siemens Energy Global has taken on this challenge and has initiated various projects.

Project requirements

The water treatment systems for electrolysis for the project were developed on the basis of detailed specifications from Siemens and manufactured according to a modular design by Wilhelm Werner GmbH.

Implementation

The central pre-treatment is performed in a complete demineralisation stage consisting of an ion exchange softener, reverse osmosis unit, membrane degassing unit and continuous electro deionisation unit. The capacity of the full demineralisation stages currently ranges from 200 l/h to 1200 l/h. In a central process water recycling plant, the hot water returned from electrolysis is degassed in a hydrogen separator and demineralised using special ion exchange processes. All process-relevant operating parameters and operating states are monitored by PLCs and displayed as graphics on the screen. The process data is sent to central control systems via an Ethernet interface.