Phased Chiller Plant Upgrade
Maintaining Continuous Manufacturing Operations
The Critical Infrastructure team at Genesis designed and executed a complex chiller plant upgrade and relocation for Takeda’s Building 5. facility. This project addressed critical operational inefficiencies and expanded thermal load capacity—all while ensuring zero downtime for essential pharmaceutical manufacturing.
A primary challenge was the high-stakes conversion of a second-floor office space into a heavy-duty, code-compliant chiller room. This required navigating intricate electrical, mechanical, and structural constraints within an active facility.
Key Technical Milestones:
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Mechanical Systems & Multi-Temp Cooling: We installed nine new high-efficiency chillers (ranging from 200 to 400 tons) and twelve pumps. The system was engineered to deliver precise process cooling at three distinct setpoints: at +6°C, -6°C, and -12°C.
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Structural Reinforcement: To support the massive operational loads of industrial chillers in a former office footprint, our team performed critical structural slab reinforcement on the second floor.
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Phased Decommissioning: To guarantee operational continuity, the new infrastructure was fully commissioned before any of the eleven legacy chillers and pumps were removed from service.
Project Results: Reliability Without Disruption
Through strategic phased execution, Genesis delivered a modern, high-capacity cooling solution tailored to the rigorous demands of life sciences manufacturing:
- Zero Production Downtime: Manufacturing remained online throughout the entire transition.
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Increased Thermal Capacity: Expanded cooling loads to support future facility growth.
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Legacy Equipment Removal: Streamlined operations by removing 22 pieces of outdated legacy equipment post-commissioning.
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Expertise in Critical Infrastructure: This project highlights our ability to execute “live” system swaps in sensitive environments where environmental control is non-negotiable.
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