Introduction: Dhanvi Infracon Pvt. Ltd., a seasoned player in industrial and commercial infrastructure development, has undertaken a monumental project to build the manufacturing headquarters for Nexcuure Private Limited. Nexcuure is a rising leader in the healthcare domain, with a diverse product portfolio that includes branded generic pharmaceuticals, nutraceuticals, and OTC (Over-the-Counter) health solutions. The facility is designed to adhere to the most stringent global standards such as WHO-GMP, USFDA, and ISO certifications, integrating both manufacturing and R&D capabilities under one sustainable, tech-ready roof.
Key Objectives of the Project:
- To construct a world-class, fully compliant manufacturing plant that meets international pharmaceutical standards.
- To accommodate various lines of product types, from tablets and capsules to softgels, syrups, and powder-based formulations.
- To build segregated zones for pharmaceuticals and nutraceuticals to ensure clean, contamination-free operations.
- To incorporate administrative blocks, R&D wings, QC labs, and warehousing facilities within the same complex.
Facility Highlights:
- Total Built-Up Area: 95,000+ sq. ft.
- Design Structure: RCC-framed structure with industrial epoxy flooring, AHU-integrated HVAC, and PEB roof structures in selected zones.
- Production Capacity: Designed for scalable manufacturing with up to 10 production lines operational simultaneously.
- Cleanroom Classification: ISO Class 7 and Class 8 for different manufacturing and packaging areas.
- Sustainability: Solar-ready rooftops, STP for water recycling, and green belt landscaping.
- Storage: Cold storage, controlled ambient storage, and high-volume raw material godowns.
Technology & Engineering Excellence:
- Cleanroom Architecture:
- Modular panel walls and ceilings compliant with GMP requirements.
- Airlocks, pass boxes, and laminar airflow systems for contamination control.
- HVAC & Utility Systems:
- Independent HVAC systems for pharma and nutraceutical zones.
- BMS (Building Management System) enabled for temperature, humidity, and pressure differential monitoring.
- Structural Engineering:
- Vibration-resistant flooring for precision manufacturing equipment.
- Load-bearing RCC slabs designed to support heavy-duty machines.
- Automation Integration:
- Integration of SCADA systems in utility control.
- IoT-enabled production lines for real-time tracking and quality checks.
- IT & Communication Infrastructure:
- High-speed LAN backbone, access-controlled server rooms, and CCTV surveillance integrated with the central command.
- Effluent & Waste Management:
- Automated Effluent Treatment Plant (ETP) and Sewage Treatment Plant (STP).
- Waste segregation units in compliance with biomedical waste norms.
Construction Challenges and Strategic Solutions:
- Regulatory Compliance:
- Challenge: Designing infrastructure to meet multiple international pharmaceutical standards.
- Solution: Collaborative approach with Nexcuure’s compliance team and pharma-specialized consultants for approvals.
- Zoning for Contamination Control:
- Challenge: Managing air, water, and human movement across pharma and nutraceutical production zones.
- Solution: Color-coded zoning, differential air pressure design, and sensor-based door control systems.
- Material Movement & Logistics:
- Challenge: Managing raw material and finished product movement efficiently.
- Solution: Seamless corridor planning with centralized material lifts and gravity conveyor integration.
- Utility Routing in a Congested Framework:
- Challenge: Routing ducts, fire lines, electrical, and compressed air systems within a compact site.
- Solution: Multi-layered BIM (Building Information Modeling) simulations to detect and prevent clashes.
- Timeline Pressure:
- Challenge: Fast-paced construction demanded by market launch commitments.
- Solution: Parallel execution of civil and finishing activities, modular construction for cleanroom installations.
Future-Ready Infrastructure:
- AI-Powered Quality Monitoring Labs:
- Provisions for robotic inspection arms and automated testing units.
- R&D Expansion Zone:
- 15,000 sq. ft. earmarked for molecular development and product innovation center.
- GMP Warehousing Extension:
- Ready-to-deploy foundations for future vertical expansion of warehousing blocks.
- International Regulatory Office Block:
- Office space created to house documentation, audits, and export licensing departments.
- Energy Transition Plan:
- Rooftop solar integration target of 250 kW by 2026.
Advantages of the Project:
- Purpose-built facility for dual-domain operations (pharma and nutraceuticals).
- Highly compliant with international health and safety standards.
- Modular design allows for scale-up of product lines with minimal civil modifications.
- Efficient material flow design boosts operational productivity.
- Advanced ETP/STP systems ensure near-zero environmental impact.
Disadvantages and Mitigations:
| Potential Drawback | Mitigation Strategy |
|---|---|
| High cost due to compliance-heavy design | Long-term benefit through low rework/retrofitting |
| Congested site area for expansion | Designed vertical expansion with pre-cast slabs |
| Specialized labor dependency | Engaged pharma-specialized EPC consultants |
| Increased utility load | Used energy-efficient systems and smart meters |
Project Management Practices by Dhanvi Infracon:
- Daily Progress Reports: Shared via cloud-based construction platforms.
- On-Site Quality Control: Independent QA team to verify stage-wise compliance.
- HSE Protocols: Regular safety audits, emergency drills, PPE enforcement.
- Vendor Coordination: Weekly syncs with MEP, HVAC, Cleanroom and Fire vendors.
- Client Review Mechanism: Bi-weekly walkthroughs and milestone validation.
Conclusion: Dhanvi Infracon Pvt. Ltd. has successfully engineered and delivered a manufacturing ecosystem that enables Nexcuure Pvt. Ltd. to scale its vision of producing affordable, world-class pharmaceutical and nutraceutical products. By adopting a strategy rooted in advanced technology, compliance-centric architecture, and sustainable construction practices, this project is positioned as a benchmark facility for the Indian and global healthcare industry. It’s not just a factory—it’s a high-functioning pharmaceutical engine ready to power the next wave of health innovation.
