Bausch + Lomb Film Capacity Expansion Phases 1 - 3

Client: Bausch + Lomb Ireland Ltd
Value: $90m
Architect: C.J. Falconer & Associates
Project Manager: Synergy Engineering for Phases 1 & 2 and C.J. Falconer & Associates for Phase 3
Project Status: Completed April 2012
 
Bausch & Lomb (B&L) are a large multinational, headquartered in Rochester New York, USA. B&L are a leading manufacturer of eye health products, including contact lenses, lens care products, medicines and implants for eye diseases.
 
Due to a change in product to be manufactured a significant upgrade and refurbishment was required to the existing facility in Waterford. This project involved the refurbishment of existing clean space (Class 100,000), an extension to the clean room and new loading bays, Laboratory areas, packaging area and plant space.
This project has to be completed in 3 phases to smooth the progress of ramping down the existing product and progressing the new product. Most of the construction work was in or close to the existing live manufacturing environment and was a significant challenge.
 
Started in 2009, Phases 1 & 2 involved the refurbishment of 2400m2 of the 3,700m2 existing clean space. The construction was phased so that significant portions of the clean space could remain in production. Synergy Engineering were the project managers and the design team lead for Phase 1 & 2 of the project.
 
Started in 2011, Phase 3 involved the refurbishment of another 730m2 of existing clean space. In addition to this, a significant new build was to be constructed with two elements. The first involved an extension of 800m2 to the clean space, fallow areas, new loading bays, packaging areas and associated plantrooms. The second extension involved laboratory and specialist storage areas and associated plantrooms. The new construction allowed for future expansion.