ADDEV Materials

The division’s operating sectors, and specifically across pharmaceuticals, life sciences, and personal care, continue to experience sustained growth, placing increasing demand on manufacturing precision, cleanliness, and flexibility. Following a major expansion of its production capabilities and relocation to larger premises, ADDEV Parafix required a new ISO certified cleanroom capable of supporting manufacturing volumes and increasingly complex converting operations.

The new environment needed to be engineered around both machine performance and controlled environmental integrity:

• Supporting multi-zone production workflows
• Maintaining strict cleanliness separation between processes
• Accommodating converting machinery
• Enabling efficient operator and material flow
• Allowing for future expansion without disruption to operations

As Richard Sincock, General Manager at ADDEV Parafix, highlighted the operational requirement clearly:

Our customers operate in highly regulated environments where consistency and contamination control are highly specific. We needed a facility that could match that expectation while allowing us to scale.

We weren’t just looking for more space. We needed a controlled environment that actively supported how our production teams work, not constrained them.

Monmouth Scientific designed and delivered a 26m x 26m facility-scale Modular Cleanroom, covering approximately 500m² of controlled production space. The solution was engineered as a fully modular, scalable system capable of supporting workflow segmentation across 15 operational zones.

These zones include entrance and exit airlocks, gowning areas, production cells, material transfer points, and dedicated packing areas, each designed to maintain controlled transitions between ISO 7 and ISO 8 classified environments.

Key technical features include:

• 26m x 14m production area with a 3.4m internal height and integrated 5m x 11m entrance and change atrium.
• 14m x 12m packing zone with four dedicated material transfer bays.
• Flexible curtain segregation enabling controlled material movement.
• ISO 7/8 zoned cleanliness strategy.
• CAMT2000 clean air modules with HEPA filtration.
• Visionaire real-time environmental monitoring system.
• Integrated LED lighting, cleanroom flooring, sliding access systems, and concealed services trunking.

A key design focus was machine layout optimisation. The cleanroom was configured specifically around ADDEV Parafix’s converting equipment, ensuring efficient operator flow, reduced material handling risk, and positioning for high-precision processes.

Installed technologies include multiple converting platforms supporting:

• High-precision die-cutting and rotary laser cutting
• Controlled multi-layer lamination processes
• High-tolerance slitting operations (±0.25mm)
• Island placement for complex adhesive assemblies
• Finished component assembly and tailored packaging workflows

Richard commented on the design approach:

The layout has completely transformed how we operate. Everything now flows logically, from raw material entry through to finished product dispatch.

The completed facility enables ADDEV Parafix to operate a fully integrated, high-precision production environment with controlled separation at every stage of manufacture.

By structuring the cleanroom into defined operational zones, ADDEV Parafix has improved process integrity while increasing throughput capacity and reducing handling complexity between production stages.

The modular nature of the installation also ensures long-term scalability. Additional zones or capacity can be integrated with minimal disruption, supporting ADDEV Parafix ’s ongoing growth.

From a production perspective, the facility now enables:

• Streamlined material flow from intake to dispatch
• Improved segregation of sensitive manufacturing stages
• Enhanced control of particulate and environmental conditions
• Greater flexibility in machine deployment and future process expansion

Commenting on the project, Lewis Irish, Sales Director at Monmouth Scientific, said:

“This project represents a significant milestone for Monmouth Scientific. Delivering our largest Modular Cleanroom to date, at this scale and complexity, demonstrates the capability and flexibility of our modular systems when applied to client challenges.”

Working closely with ADDEV Materials, the focus was on ensuring the environment supported both current manufacturing requirements and long-term operational growth. The result is a highly controlled, multi-zone facility that achieves exactly that.

Richard noted the operational impact:

This facility gives us confidence in both our current capability and future growth. We now have a platform that can evolve with our customers’ needs.