Modular Process Skid Engineering for Biopharma | 30 % Faster Installation 

The manufacturing landscape has fundamentally shifted over the past decade. Efficiency, flexibility, and scalability have transformed from competitive advantages into baseline requirements for survival. At Noreside Engineering, we’ve observed this evolution first-hand, particularly noting how modular process skids have revolutionised industrial design across the pharmaceutical and food & beverage sectors.

What Are Modular Process Skids?

Modular process skids are pre-fabricated, self-contained process units that integrate key components—pumps, heat exchangers, filtration systems, control panels, and instrumentation—onto a single structural frame. These compact, transportable systems arrive on-site fully assembled, tested, and ready for operation with minimal installation requirements.

The Evolution of Modular Solutions in Manufacturing

Traditionally, process systems were constructed on-site, requiring extensive planning, coordination of multiple contractors, and lengthy facility downtime. The shift towards modular design represents a fundamental rethinking of how processing facilities are built and maintained.

At Noreside Engineering, our decades of experience in skid manufacturing has positioned us at the forefront of this transformation, particularly in our specialist areas of pharmaceutical and food & beverage processing.

Key Advantages of Modular Process Skids

1. Accelerated Project Timelines

Factory-built skids dramatically reduce installation time compared to traditional stick-built systems. While on-site construction progresses, our team simultaneously builds and tests your processing equipment in our controlled facility, effectively compressing project schedules by up to 40%.

2. Superior Quality Control

Our controlled manufacturing environment eliminates many variables that plague on-site construction. Every skid undergoes rigorous testing and validation before leaving our facility, ensuring compliance with all relevant standards, including GMP, ASME BPE, 3-A Sanitary Standards, and EHEDG guidelines.

3. Reduced Validation Time for Pharmaceutical Applications

For our pharmaceutical clients, one of the most significant advantages of our modular approach is the ability to perform Factory Acceptance Testing (FAT) prior to delivery. This comprehensive testing substantially reduces the scope of Site Acceptance Testing (SAT) and subsequent validation activities, accelerating time-to-market for critical medications and treatments.

4. Future-Proof Flexibility

As we’ve previously discussed in our exploration of Industry 4.0 integration, manufacturing facilities must adapt to evolving technologies and market demands. Modular skids facilitate this adaptability, allowing for easier upgrades, reconfigurations, or relocations as production requirements change.

Noreside’s Specialised Expertise in Skid Manufacturing

Over two decades, Noreside Engineering has refined our approach to modular skid design and fabrication, particularly for the unique requirements of pharmaceutical and food & beverage processing. Our expertise encompasses a wide range of applications.

For pharmaceutical clients, we design and build WFI generation systems, clean steam generation, buffer preparation, chromatography skids, ultrafiltration systems, CIP/SIP systems, and bioreactor systems.

Our food and beverage offerings include pasteurisation units, filtration systems, blending stations, CIP systems, separation technology, homogenisation equipment, and ingredient handling systems.

Case Study: Rapid Deployment for a Leading Irish Pharmaceutical Manufacturer

When a prominent Irish pharmaceutical company needed to quickly expand production capabilities for a critical new drug formulation, they turned to Noreside Engineering for a solution.

The challenge: Design, build, and commission a complete buffer preparation system within a compressed six-month timeframe to meet market demand.

Our approach utilised our modular skid methodology to develop detailed 3D models for virtual integration with the client’s facility. We pre-fabricated components while site preparations were underway and conducted comprehensive Factory Acceptance Testing with client representatives. The system was delivered and installed with minimal disruption to existing operations, with commissioning and qualification executed in parallel with other construction activities.

The result was a fully operational buffer preparation system delivered two months ahead of traditional construction estimates, allowing our client to meet their production targets and market commitments.

The Future of Modular Process Engineering

As manufacturing continues to evolve, we see several emerging trends in modular process design:

Increased Integration of Automation and Digital Technologies

According to McKinsey & Company’s research on digital manufacturing, manufacturers implementing Industry 4.0 technologies can increase productivity by up to 40%. Our modular skids increasingly incorporate advanced automation, data analytics capabilities, and remote monitoring systems.

Sustainability-Focused Design

Environmental considerations are becoming central to process design. Modular systems often demonstrate superior efficiency in energy and water usage, with some systems achieving up to 30% reduction in resource consumption.

Expansion of Application Areas

While pharmaceuticals and food & beverage industries have been early adopters, we’re now seeing increased interest from adjacent sectors. These include speciality chemicals, cosmetics manufacturing, alternative protein production, and advanced materials processing.

Partner with Noreside for Your Modular Process Needs

At Noreside Engineering, we combine deep industry knowledge with cutting-edge modular design principles to deliver process solutions that exceed expectations. Our comprehensive approach includes initial consultation, detailed design, fabrication and assembly, testing and validation, installation and commissioning, and ongoing support.

Whether you’re planning a new facility or upgrading existing processes, our team is ready to help you harness the transformative potential of modular process skids.

Contact our specialists today to discuss how we can support your specific processing requirements.

Noreside Engineering specialises in the design and manufacture of stainless steel process equipment and modular skid units. Our industries include the pharmaceutical & food, beverage industries. We serve clients in Ireland, the UK and around the world. 

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