Mayne Pharma - Pharmaceutical Manufacturer

Major pharmaceutical’s sliding and swing door solutions for clean room airlocks ensure an efficient and safe working environment

ASSA ABLOY Entrance Systems, providing a single point of contact to facilitate communication and project management, consulted in close partnership with Mayne Pharma on a packaged door solution. The door packages include clean room sliding doors, swing doors and swing door operators, rolling steel fire rated coiling doors, strip curtains and all door frames and associated hardware.

Background

Greenville N.C.—considered the medical hub of eastern North Carolina—is home to Mayne Pharma’s new 126,000-square-foot, large-scale manufacturing facility.  The pharmaceutical company’s Greenville Campus expansion project, completed in late 2017, now allows Mayne Pharma a comprehensive concept-to-commercialization solution in a single contiguous site.


Mayne Pharma specializes in the formulation development, analytical testing, and clinical trial manufacturing of oral and topical dosage pharmaceuticals.  The drug manufacturer has the capacity to produce more than one billion tablets and capsules annually.


Critical to Mayne Pharma’s manufacturing operation is ensuring the mitigation of cross-contamination risks and handling of highly potent compounds in strict adherence to U.S. Food and Drug Administration Current Good Manufacturing Practice (cGMP) regulations. 


Challenge

Mayne Pharma’s plans to expand its pharmaceutical drug manufacturing operation in Greenville, N.C. centered on delivering enhanced solutions for its clients. That meant Mayne Pharma called for the latest in specialty entrance doors within its newest production facility.


In particular, airlock ingress/egress for the facility’s 27 clean room production labs required parallel sets of doors.  Among several key requirements were sliding doors that are aesthetically pleasing, easy to clean, operate efficiently, feature both high reliability and quiet operation, and occupy a minimal amount of space to permit unencumbered movement between areas of different pressures.


In addition, Mayne Pharma required customized surface mounted door operators on its new double swing doors.  They allow each door leaf to open a full 180 degrees to provide easy and efficient ingress/egress of personnel transporting large bulk material handling equipment.  

Requirements

  • Space-saving door solutions for both ends of clean room airlocks as well as numerous other internal corridor door opening locations.
  • Sliding doors for entry into clean room airlocks from the corridor side along with a parallel set of swing doors on the opposite end of each airlock that provide entry into the clean room production labs themselves.
  • ¼” clear tempered glass in the sliding doors for additional strength.
  • Compressible, reliable vinyl door seals that are removable and replaceable for easy maintenance.
  • Proper sequencing for sliding and swing doors so that only one set of doors will open at one time to maintain air quality inside the airlocks and in the clean room production labs.
  • Push plates for personnel to operate all doors.
  • Infrared sensors on swing doors to prevent door leaves from hitting personnel or other obstructions.
  • Fire alarm integration for all doors.

Solution

ASSA ABLOY Entrance Systems, providing a single point of contact to facilitate communication and project management, consulted in close partnership with Mayne Pharma on a packaged door solution.  The doors package includes clean room sliding doors, swing doors and swing door operators, rolling steel fire rated coiling doors, strip curtains and all door frames and associated hardware.  Total quantities for the entire Mayne Pharma doors package includes: 

  • 27 ASSA ABLOY SL500 clean room sliding doors (surface-applied bi-parting active leaf only configuration) with ¼” tempered glass
  • 35 pairs of ASSA ABLOY SW200i surface mounted automatic swing door operators
  • 4 rolling steel fire-rated coiling doors
  • 4 strip curtains• 225 openings (includes all frames, doors and associated hardware)

Result

ASSA ABLOY Entrance Systems partnered closely with both Mayne Pharma’s facilities director and the project’s general contractor to provide a high level of due diligence prior to product installation.  This also ensured that all clean room sliding door and swing door locations, along with surface mounted door operators where required, were properly prepared for product installation and operation.  Various concerns included epoxy floors, all electrical and associated controls, as well as all finished surfaces that would receive surface mounted door operator hardware.   


The result was an smooth installation process that now includes airlocks with both sliding doors and swing doors on each end.  The doors and their compressible vinyl seals help to effectively balance the air pressure between the facility corridor (on the sliding door end of the airlock) and each clean room production lab (on the swing door end of the airlock).  The sliding doors also allow for unobstructed two-way traffic in all corridors.


In addition, the swing door operators always know the position of the doors in relation to each open/close cycle.  This means the swing door operators will automatically compensate for whatever stack pressure the doors encounter with either opening or closing.


Mayne Pharma is anticipating that its new clean room sliding doors will result in a 50 percent savings in door damage and maintenance costs (compared to double metal doors) as well as a lower total cost of ownership over the products’ lifetime.


For more information about this project, please contact: marketing.na.entrance@assaabloy.com

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