Following the successful first phase of a 2Clean XXL washer installation at a pharmaceutical manufacturing site in the Northeast of England, Stage Two of the project saw the installation of a bespoke 2Clean XL Contact Part and IBC Washer within the Dries area of the facility. This second-stage investment reinforced our client’s commitment to hygienic design, validated cleaning performance and future-proofed manufacturing operations.

Supporting a High-Volume Pharmaceutical Environment

Our client manufactures many globally recognised healthcare brands, including Nurofen, Gaviscon and Strepsils. Across the production process, IBC bins are used to transport granulated powders prior to tablet pressing and packaging. These bins must be cleaned thoroughly between every batch to maintain product quality, regulatory compliance and operational efficiency.

The existing washer in the Dries area had reached the end of its serviceable life. Its outdated design and increasing maintenance demands made it unsuitable for modern pharmaceutical production. Building on the success of the first phase of the project, our client selected the 2Clean XL as the ideal solution for Stage Two.

The 2Clean XL: Hygienic Design with Built-In Flexibility

The 2Clean XL was chosen for its ability to wash both large IBCs and smaller contact parts within a single hygienic platform. Manufactured with mirror-finished stainless-steel internals polished to 0.5µ Ra, the washer features a single-welded construction that eliminates contamination traps and supports validated cleaning processes.

Customisation was a key requirement, with the chamber sized to accommodate one particularly large IBC used in the Dries area. This tailored approach ensured the new washer aligned precisely with their existing production infrastructure while providing long-term flexibility.

Precision Installation in a Restricted Space

 The installation of the 2Clean XL presented several logistical challenges, making it a true test of engineering expertise. Space within the Dries area was extremely limited, requiring careful planning and coordination to deliver the machine safely and efficiently.

To allow the chamber to enter the building, part of the external wall was temporarily dismantled, creating a controlled access point. The main chamber, manufactured as a single piece in line with pharmaceutical fabrication standards, was then moved into position on low-level skids and lowered directly into a newly constructed pit.

Despite these constraints, installation and mechanical assembly were completed within two weeks, ensuring minimal disruption to ongoing manufacturing operations.

Commissioning, Validation and Compliance

Commissioning of the 2Clean XL was completed, following the same proven methodology established during Stage One of the project. The process included:

• Final software configuration
• Verification of wash cycles and utilities
• Full SAT / IQ / OQ validation
• 100% alarm testing

All activities were completed successfully, allowing the washer to be released into production with full confidence in its performance and compliance.

Empowering Operators Through Training

As the final step in Stage Two, comprehensive training was delivered to our client’s operators and maintenance technicians. Training focused on safe operation, routine maintenance and servicing procedures, ensuring the washer continues to perform optimally throughout its lifecycle.

 A Successful Second Stage, A Long-Term Solution

 The installation of the 2Clean XL marked the successful completion of Stage Two of our client’s washer upgrade programme. With enhanced hygiene, reduced   maintenance demands, and increased operational flexibility, the new washer now plays a critical role in supporting high-quality pharmaceutical production within the Dries area.

Proven Capability in Live Pharmaceutical Environments

Our projects demonstrate more than equipment supply; they prove our ability to engineer, install and validate hygienic wash solutions within live, high-compliance manufacturing environments. When space is limited, timelines are critical and standards are uncompromising, we deliver.

Have a challenging installation or bespoke requirement?

Discover how our project expertise can support your facility