Piramal Healthcare Morpeth – GRP Cooling Tower Replacement | Vistech Case Study
Cooling Tower Replacement Enabling Continuous Operation and Reduced Lifecycle Risk
Vistech Cooling Systems delivered a full cooling tower replacement for Piramal Healthcare’s Morpeth pharmaceutical manufacturing facility, replacing ageing timber towers with a modern GRP-based system.<br />
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The new installation significantly improves cooling efficiency, reduces operational costs and eliminates the maintenance and compliance risks associated with timber construction. Designed for operational resilience, the four-tower configuration enables continuous plant operation during maintenance, ensuring uninterrupted production in a regulated pharmaceutical environment.
The Challenge
Piramal Healthcare’s existing cooling infrastructure consisted of ageing timber cooling towers that had become increasingly inefficient and maintenance-intensive. The deterioration of the timber structure resulted in frequent shutdowns, increased operational costs and reduced system reliability.
The porous nature of the timber construction created an elevated risk of bacterial growth, presenting potential health, safety and regulatory compliance concerns within a pharmaceutical production environment.
Operationally, the system lacked flexibility, requiring full shutdowns for maintenance activities, directly impacting production continuity. In addition, the original tower location introduced access and logistical constraints, limiting effective maintenance and future system optimisation.
The project therefore required a complete system replacement capable of improving efficiency, eliminating compliance risks, and enabling continuous operation, all while integrating with existing plant processes.
The Solution
Vistech designed and delivered a fully integrated cooling solution based on four EWK 1260/09 GRP cooling towers, engineered to provide improved efficiency, reliability and maintainability in a pharmaceutical manufacturing environment.
The system was strategically relocated to optimise access, performance and long-term maintainability, supported by new civil works and structural infrastructure.
Key Technical Features:
- GRP cooling tower construction eliminating corrosion, decay and long-term structural degradation associated with timber systems
- Anti-legionella fill media, drift eliminators and biocide-impregnated casing to mitigate bacterial growth and support regulatory compliance
- Variable speed fan motors and pumps operating via inverters, dynamically adjusting to process demand to optimise energy efficiency
- Four-tower configuration enabling staged operation, allowing individual units to be isolated for maintenance without interrupting plant operation
- Integrated remote monitoring and control systems providing real-time performance data and enabling proactive maintenance
- Custom-designed civils, steelwork, pipework and control systems to ensure seamless integration with existing plant infrastructure
The solution delivers a future-proofed cooling system that aligns with pharmaceutical industry requirements for reliability, hygiene and operational continuity.
Scope of Works
Cooling Towers
Design, supply and installation of 4 x EWK 1260/09 GRP cooling towers
Civils & Foundations
Site preparation, structural assessments and civil works for new tower location
Support Steelwork
Design and installation of structural steel supports
Pipework
Design and installation of process pipework connecting towers to plant systems
Electrical & Controls
Integration of inverter-driven motors, control systems and remote monitoring
Access & Safety
Access platforms, walkways and maintenance provisions
Commissioning
Testing, validation and system commissioning
Programme
Site Preparation
Ground surveys, civils and structural works
Installation
Assembly and positioning of cooling towers and steelwork
Mechanical Works
Pipework installation and system integration
Electrical Works
Control systems, inverters and monitoring installation
Commissioning
Testing, validation and handover
“The system has been designed so any one of the four cooling towers can be shut down for maintenance or cleaning, with the remaining three towers able to supply the full required duty. A big thank you to the Piramal Engineering teams together with Vistech Cooling Systems in delivering a state-of-the-art, energy-efficient £1.5M investment, and to SUEZ UK for delivering the chemical dosing system.”
— Martin Graham, Piramal - Director of Engineering