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Discovery to Delivery

Esco Pharma News

News Turnkey Dismantling, Modification, and Relocation of a Multi-Glove Isolator System for a Biopharma Manufacturer

Turnkey Dismantling, Modification, and Relocation of a Multi-Glove Isolator System for a Biopharma Manufacturer

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Turnkey Dismantling, Modification, and Relocation of a Multi-Glove Isolator System for a Biopharma Manufacturer

Case Study: Turnkey Dismantling, Modification, and Relocation of a Multi-Glove Isolator System for a Biopharma Manufacturer

Client: Confidential
Industry: Biopharmaceutical Manufacturing
Project Locations: Northeastern United States, to Esco USA Facility in Pennsylvania, to Gulf Coast of the United States
Project Duration: 4 Months
Date: June 2025


Project Overview

A leading biopharmaceutical manufacturer partnered with Esco team to manage the end-to-end dismantling, retrofit, and relocation of a critical isolator unit. The project scope included equipment disassembly, custom modifications, interstate logistics, and final installation at a GMP production facility—requiring expert coordination and strict compliance with regulatory standards.

Executed across three separate locations, this complex, multi-stage operation was completed with zero disruption to ongoing operations and full adherence to GMP protocols. Ultimately, the client saved over 50% of the capital cost of a new sterility test isolator and shortened lead time by 3 to 4 months. Furthermore, the isolator was delivered with a new factory warranty.


Objectives

  • Safely dismantle and cleanly remove a 5-glove isolator system from a production site.

  • Retrofit the unit to support the latest sterility testing pump with footswitch integration.

  • Install custom 316 stainless steel racking and shelving in both the transfer and main chambers.

  • Professionally crate, transport, and reinstall the modified unit at a new biomanufacturing facility.

  • Re-commissioning and perform new Installation and Operation Qualification (IQ/OQ).


Project Execution Summary

  1. Dismantling & Removal (Client Facility – Northeastern U.S.)

    Esco technicians provided all labor and equipment necessary to safely dismantle and extract the isolator system. All activities were completed in accordance with site-specific safety procedures and contamination control protocols.

  2. Packing, Crating & Transport (From Client Facility – Northeastern U.S. to Esco Facility – Pennsylvania)

    Following disassembly, the unit was securely packed and crated for transport to the original equipment manufacturer (Esco) for factory-authorized modifications.

  3. Technical Modifications (Esco Facility – Pennsylvania)

    At the Esco facility, the isolator was modified to accommodate a modern sterility testing pump, complete with integrated footswitch control. Additionally, high-grade 316 stainless steel shelving systems were custom-fabricated and installed within the isolator's chambers to improve workflow and capacity.

  4. Re-Crating & Delivery to Final Site (To Client’s New Facility – Gulf Coast U.S.)

    The upgraded isolator was professionally re-crated and shipped to the client’s new production facility in the Gulf Coast region.

  5. Final Delivery & Installation (Client’s New Facility – Gulf Coast U.S.)

    Upon arrival, the Esco team managed unloading, internal relocation, placement, and final alignment of the unit according to the client’s designated production layout and specification.

  6. Validation and Qualification

    Following successful installation, the team fully recommissioned the equipment and delivered a new IQ/OQ document, enabling the client to proceed to PQ and production testing.


Challenges and Solutions

This project presented several critical challenges that required precise planning, expert coordination, and innovative solutions to ensure successful execution without disrupting operations. One of the primary challenges was the cross-country transport of fragile, high-value pharmaceutical equipment. To safeguard the isolator system during transit, the Esco team designed and employed shock-absorbent crating, utilized real-time shipment tracking, and leveraged specialized handling equipment, ensuring the unit arrived at each location protected and on schedule.

Integrating legacy equipment with modern production tools posed another significant hurdle. Our team worked closely with the client’s engineering groups to ensure functional compatibility while maintaining regulatory compliance throughout the process.

Finally, the project demanded strict adherence to tight timelines and GMP standards across multiple sites. To meet these requirements, the Esco team developed a detailed project execution plan featuring built-in quality assurance and control checkpoints, along with contingency measures—enabling seamless coordination and zero disruption.


Conclusion

Esco successfully delivered a complex, multi-site equipment relocation while meeting strict regulatory and operational requirements. Through close coordination, expert engineering, and GMP-focused execution, the team ensured a smooth transition from dismantling to final qualification.

The client not only accelerated deployment timelines by 3 to 4 months but also significantly reduced more than 50% capital expenditure of sourcing a brand-new isolator system. With upgraded functionality, full compliance, and a renewed factory warranty, the delivered solution met all production and regulatory demands, with zero disruptions to ongoing operations.

Esco’s end-to-end approach, combining custom engineering, regulatory expertise, and coordinated execution, reinforced the value of revitalizing existing assets to meet modern pharmaceutical standards in a cost-effective, time-efficient manner. 

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