Flexiscreen at 45ft: contamination control in active pharmaceutical facility

Clean separation in a live pharmaceuticals facility

A global pharmaceutical company needed to construct and install a new industrial freezer inside an active, tightly controlled facility. In pharmaceutical manufacturing, where contamination events can trigger product recalls, regulatory investigations and serious reputational damage, there was no margin for error. Having worked with Westgate Global before, the company and their engineering consultants knew who to call.

No downtime. No dust. No margin for error.

The project required a floor-to-ceiling separation screen installed without causing downtime or compromising the strict hygiene standards the site demanded. The programme was planned to run for 12 months, during which the facility needed to remain live, clean, and fully operational. To complicate matters further, the project began during the COVID-19 pandemic, which ruled out standard on-site surveying from the outset.

Floor-to-ceiling protection, built around a live operation.

Westgate Global specified Flexiscreen as the primary separation system. With just two skilled installers and a Mobile Elevating Work Platform required for installation, it was installed cleanly and quickly without the heavy plant or prolonged preparation time that alternative solutions would have required.

Flexiscreen’s v-overlap system delivers a 99%+ dust-tight seal and can be fitted neatly around high-level services. Despite being installed at the facility’s full 45ft height, there was no need for additional mid-span support structure, which meant that the working area around the new freezer installation was clear and accessible.

The screen was designed to include a fire escape access door, which was fitted with a digilock for CDM compliance and a fire escape push pad. With a tensile strength of 2000lbs per linear ft, the system absorbs impact and keeps maintenance requirements low. As a one-off purchase, the client avoided the ongoing rental costs and periodic safety checks that alternative temporary solutions would have required.

Given the sensitivity of the site, a 10ft free-standing PVC partition was also installed in front of the Flexiscreen as a secondary line of defence, creating an additional physical barrier to provide maximum protection against contamination and unplanned access.

With on-site surveying not possible during the pandemic, the entire solution was designed and manufactured remotely using 3D drawings supplied by the client. Installation was complete four weeks from order.

Compliant, award-winning installation

From first installation to final sign-off, the facility remained clean, compliant, and fully operational. The engineering consultancy managing the project recognised Westgate Global’s safe working with their SafeContractor of the Month award, on a site where standards are exceptionally high.

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