Becton Dickinson: A New “Energy Hub” to Power the Plant
Ranked among the world’s top five leaders in “health tech,” the American giant Becton Dickinson has been constantly innovating since its founding in 1897. In Pont-de-Claix, in the Isère department, its production facility for syringes and piston seals reflects its ambitions. Now more relevant than ever, this operation has undergone an extraordinary renovation, including the construction of a turnkey “Utilities” building designed by Equans France.
The strategic division of the U.S. group
Just imagine: 18,000 m² of production facilities and 4,000 m² of cleanrooms spread across nearly 10 hectares of land! Located in Pont-de-Claix, in the Isère department, the Becton Dickinson site is THE strategic hub of the American group.
Every year, more than 330 million glass syringes and 1,800 million piston seals are manufactured here and then shipped to nearly 300 countries. These two strategic products require a high level of R&D and engineering, both in terms of technology and manufacturing processes. A single “grain of sand” is enough to jam the entire production line, triggering a domino effect that leads to a total or partial halt in production. Unthinkable for the American giant!
Especially since Becton Dickinson intends to continue its international growth strategy. The only solution: to overhaul the entire production and utility distribution chain, which relies on a multitude of small units, each very different from the others.
A Major Challenge
The stakes are high: the goal is not only to modernize the production facility but also to offer a more energy-efficient and sustainable solution.
The result: improved performance and reduced maintenance. But how can we ensure the secure production and distribution of utilities?
How can we make maintenance easier? And how can we do all of this with a “low-carbon” approach?
To address this challenge, Equans France turned to the design and construction of a turnkey building that centralizes the “utilities”:
- Thermal fluids (chilled water, hot water)
- Electrical power (transformer and main distribution panel)
A Strategic Asset
A true strategic “hub,” this 300 m² building—adjacent to the manufacturing site—centralizes all heat, cooling, and electricity production in a single location and then redistributes the energy generated.
The result of a collaborative effort between “the cooling experts” and “the electrical teams,” this complex project brings together Equans France’s diverse areas of expertise to serve its clients.
Early on, the teams first conducted a collaborative value engineering effort to better understand Becton Dickinson’s challenges and expectations. With all due respect to Henry Ford, the father of mass production, this “user-centric” approach optimizes production and performance by using equipment tailored to the client’s specific needs and challenges.
Redistribute the energy produced
For Becton Dickinson, for example, the large number of units compounded maintenance issues without ensuring optimal performance. Hence the decision to consolidate the various units into a single location. Serving as the nerve center of the Isère site, this “energy hub” features three 1.2 MW air-cooled chillers, including two Quantum units with magnetic bearings. “In addition to their acoustic performance and low-carbon design, the Quantum units stand out for their high energy efficiency. Another 1.3 MW water-cooled Quantum chiller rounds out the system,” notes Sébastien Malugani, Sales Manager at Equans France.
Beneath this high-tech facility, a 5.8 MW gas-fired boiler room is connected to a 50-meter-long pipe rack. “These pipes distribute thermal energy to the site’s 50 air handling units. Needless to say, this is a critical aspect, as no temperature errors are permitted in this controlled environment.”
A turnkey system for a customized solution
To add to the project’s challenges, the teams were working on a tight schedule: 18 months to complete the CUP (Centrale Utility Production) building, including the design phase. Mission accomplished!
To facilitate collaboration and communication, Becton Dickinson had a single point of contact responsible for coordinating among the various stakeholders: civil engineering, structural work, cladding, production units, and more. That is the key advantage of a turnkey “Utilities” project.
“ “The CUP is, above all, a contractual commitment based on a price and a schedule. Throughout the project, the client has a detailed overview of their project, with no unpleasant surprises. It truly saves time, money, and improves performance.” ”
The Isère facility continues to pursue its strategy of development and innovation
With its new “hub,” the Isère-based facility is continuing its strategy of growth and innovation in the French “medtech” market. The group now has 70,000 employees worldwide, spread across more than 190 countries, with revenue in France totaling nearly 1,138 million euros in 2019.
Equans France is doing everything possible to ensure plant performance, optimize building comfort, and facilitate maintenance. This support allows Becton Dickinson to focus on its core business.