SSL International PLC
Ai Process Designs, Builds, and Commissions Medical Manufacturing Facility to Support SSL International’s Consolidation of Production Operations
Client:
SSL International
Industry:
Life sciences & healthcare
Project Site:
Peterlee, UK
Objective:
Relocation of existing manufacturing processes into new purpose built medical manufacturing facility.
At the time of the project, SSL International was a prominent biomedical manufacturer employing approximately 3,000 staff. The company had been formed just one year earlier through the merger of the Dr. Scholl footcare business, the Seton Healthcare group and the venerable London International Group (owner of the flagship Durex condom brand).
SSL International marketed and manufactured a broad portfolio of consumer‑health and personal‑care products — including condoms (Durex), footcare and footwear (Scholl), surgical and household gloves, antiseptics and other over‑the‑counter medicines.
By that point, SSL International was strategically repositioning itself to prioritise global healthcare brands over lower‑margin manufacturing, while operating both in the UK and internationally.
Ai Process Scope of Works
Ai Process delivered a full turnkey EPCM (Engineering, Procurement, and Construction Management) package, including:
- Bulk raw material storage and handling systems
- Production and tablet manufacturing infrastructure
- Filling and packaging lines
- Process utilities and service infrastructure
- Steelwork and civils
- Electrical integration
- Recipe-driven process control systems (PLC/SCADA) for all workflows
- Coordination and completion of commissioning across all process sections
Outcome and Benefits
Seamless integration builds operational agility
Comprehensive integration of utilities, process equipment, and recipe-driven control systems created a highly responsive and flexible manufacturing environment. Automated batch sequencing, coordinated material transfers, and improved equipment interoperability reduced downtime and accelerated changeovers. This operational agility enabled SSL International to manage fluctuating production demands efficiently while maintaining robust control over process accuracy.
Efficient consolidation of multiple product lines
Centralising production into one purpose-built facility enabled SSL International to streamline operations previously spread across multiple sites. This consolidation reduced duplication of equipment, simplified material handling, and improved coordination between product lines. The unified layout enhanced workflow efficiency, reduced internal logistics costs, and created a more controlled and consistent manufacturing environment.
Strong regulatory and quality alignment
Ai Process designed all process areas — from raw material handling to finished packaging — to meet biomedical manufacturing and hygiene standards. Validated workflows, hygienic construction materials, and integrated traceability safeguards improved audit readiness and product integrity. The upgraded facility strengthened SSL’s long-term compliance posture, ensuring reliable and repeatable quality across all product categories.
Turnkey project delivery
Ai Process delivered the full EPCM package — design, procurement, fabrication, installation, and commissioning — under a coordinated single-source approach. Off-site manufacturing of key assemblies reduced on-site disruption, while phased commissioning ensured a smooth transition into operation. This turnkey delivery model provided SSL with predictable timelines, cost control, and a fully validated manufacturing facility.
