Revamping and Expanding Pharmaceutical Facilities: Modernising Production Plants Without Interrupting Operations

Revamping and Expanding Pharmaceutical Facilities: Modernising Production Plants Without Interrupting Operations

Spain’s pharmaceutical industry is experiencing a period of sustained growth and transformation. Increasing production capacity, continued investment in innovation, and the need to comply with evolving technological and regulatory standards are driving the modernisation of existing manufacturing facilities across the country.

However, expanding production capacity or upgrading a pharmaceutical facility does not necessarily require building a new plant from scratch. In many cases, the greatest challenge lies in revamping an existing pharmaceutical facility or expanding an operational manufacturing site while maintaining uninterrupted production.

In these projects, the priority is clear: ensuring operational continuity. Any unplanned shutdown can disrupt manufacturing processes, while even minor incidents in controlled environments may compromise product quality, regulatory compliance and operational efficiency.

As a General Contractor specialising in complex industrial projects, GSE Iberia delivers these interventions through its integrated Design & Build model, combining engineering, construction, project planning and overall project management under a single point of responsibility.

The Challenges of Modernising an Operational Pharmaceutical Facility

Upgrading an operational pharmaceutical plant is among the most demanding types of industrial construction project.

Unlike a greenfield development, where a new facility is built from the ground up, refurbishment and expansion projects must be carefully integrated into an existing manufacturing environment, ensuring that ongoing operations remain unaffected.

Bringing an operational facility into compliance with Good Manufacturing Practices (GMP) requires meticulous planning and advanced risk management throughout every stage of the project.

The main challenges include:

• Interference control and operational safety

During retrofit or expansion works, it is essential to separate construction areas from active production areas. Proper planning makes it possible to manage access, material movements and construction activities in order to minimise interference with existing processes.

In particularly sensitive environments such as clean rooms, laboratories or pharmaceutical production areas, coordination between construction, engineering and building services is essential to maintain the required quality standards.

• Integration of new systems and installations

The revamping of a pharmaceutical plant does not merely involve renovating spaces or replacing equipment. In many cases, it involves upgrading the building’s technical installations to meet new production and regulatory requirements.

The integration of HVAC systems, utility networks, new production areas or more energy-efficient solutions requires a comprehensive approach that takes into account the interaction between the building, its installations and industrial processes.

• Expansion of laboratories and production areas: phased planningAmpliación de laboratorios y áreas productivas: planificación por fases

One of the differentiating factors in pharmaceutical expansion projects is the ability to organise the works in phases, allowing operations to continue while the work is carried out.

Digital tools play a fundamental role in managing this complexity.

Through BIM methodology (Building Information Modeling) and 4D planning, it is possible to simulate not only the final building, but also the evolution of the project during each stage of construction.

This makes it possible to:

• anticipate potential interferences before work begins;
• coordinate the arrival of machinery and materials;
• organise flows within active facilities;
• optimise execution times;
• and reduce the impact on existing production.

The combination of digital planning and construction experience makes it possible to carry out industrial expansions in a more efficient, safe and controlled manner.

Industrial retrofit: energy efficiency and sustainability

The modernisation of pharmaceutical facilities also represents an opportunity to improve energy efficiency and reduce the environmental impact of existing assets.

The industrial sector is moving towards more efficient buildings, with lower energy consumption and aligned with the ESG criteria demanded by companies, investors and end users.

In this context, retrofit projects make it possible to incorporate:

• solutions to improve energy performance;
• more efficient technical systems;
• the integration of renewable energy;
• the optimisation of resource consumption;
• more sustainable materials and construction processes.

These actions can also contribute to obtaining environmental certifications such as LEED or BREEAM, which are increasingly present in the development of new-generation industrial facilities.

GSE Iberia: a comprehensive partner for the evolution of the Life Science sector

The transformation of an existing pharmaceutical plant requires much more than construction capabilities. It demands technical expertise, planning, coordination and a comprehensive vision of the entire project lifecycle.

As a General Contractor, GSE Iberia supports its clients from the initial analysis and design stages through to the final handover of the facility, offering:

• A single point of contact: comprehensive coordination of engineering, construction and project management.
• Cost and schedule control: precise planning to reduce uncertainties during execution.
• Multidisciplinary expertise: specialised teams capable of integrating architecture, installations and production requirements.

In a sector where innovation and the ability to adapt are essential, revamping should not be viewed as a limitation, but as an opportunity to evolve.

Modernising an existing facility makes it possible to increase competitiveness, improve efficiency and prepare industrial assets for the future challenges of the pharmaceutical industry.

Case study: the expansion of Fedefarma, a project supporting the growth of the pharmaceutical sector

The ability to adapt and expand existing facilities is essential in order to respond to the new requirements of the pharmaceutical supply chain. One example is the project developed by GSE Iberia for Fedefarma, one of Spain’s leading pharmaceutical distribution cooperatives.

Following the construction of its logistics centre located in Palau-solità i Plegamans, Barcelona, GSE Iberia has once again collaborated with Fedefarma on a new expansion project designed to strengthen the operational capacity of its facilities and support the company’s growth.

The project includes the construction of an 11,879 m² extension, integrated with the existing building and developed with the aim of increasing the centre’s logistics capacity while maintaining the continuity of its operations.

This type of intervention requires precise planning and a high level of technical coordination, as it is carried out on fully operational assets where minimising any interference with daily activity is essential.

Through its Design & Build model, GSE Iberia coordinates every phase of the project, from engineering and planning to the execution of the works, ensuring the integration of the new installations with the existing infrastructure and guaranteeing compliance with the quality, efficiency and sustainability standards required by the sector.

The Fedefarma project demonstrates how the expansion of pharmaceutical facilities makes it possible to evolve existing assets, making them more competitive, increasing their capacity and preparing them for future market requirements.