Thornton & Ross Ltd
Ai Process Design, Install & Commission a New Chilled Water System to Support Pharmaceutical Production Expansion at Thornton & Ross Ltd
Client:
Thornton & Ross
Industry:
Pharmaceutical & biomedical
Project Site:
Huddersfield, UK
Objective:
Install and commission a new chilled water system to enhance pharmaceutical production reliability
Thornton & Ross Ltd is one of the UK’s largest pharmaceutical manufacturers, producing a wide range of prescription and over-the-counter medicines and healthcare products. Founded in 1922 by Nathan Thornton and Phillip Ross in Huddersfield, the company has grown from a small “manufacturing chemist” supplying pharmacists to a major national manufacturer.
Today, Thornton & Ross develops, manufactures and supplies a broad portfolio — branded consumer products such as Covonia, Zoflora, Hedrin, Savlon and Cetraben, as well as generics and specialty medicines used in areas including dermatology, respiratory, bone-health, and more.
Ai Process Scope of Works
- Detailed design, supply, installation & commissioning of a new chilled water system
- Removal of redundant infrastructure and installation of a new 5,000 L buffer tank and 200 kW chiller
- Full mechanical, electrical, and civil works including pumps, pipework, steelwork, insulation and instrumentation
- ATEX-compliant upgrades to support hazardous area classification requirements
- Process control hardware & software modifications including FDS documentation
- Project management, calibration, testing, commissioning, and operator training
Outcome and Benefits
Enhanced Production Reliability & Business Continuity
Ai Process improved chilled water resilience by installing a modern, high-efficiency 200 kW chiller paired with a 5,000 L buffer tank designed specifically for the demands of pharmaceutical production. The upgraded system mitigates risks associated with ageing utilities and unplanned downtime, ensuring stable temperature-controlled conditions essential for batch integrity GMP compliance, and uninterrupted manufacturing. This upgrade strengthened long-term business continuity planning and reduces risk of product loss due to temperature deviations.
Reduced Water Consumption & GMP Compliance
The chilled water system upgrades were carried out in alignment with pharmaceutical site safety expectations providing greater confidence in ongoing GMP compliance. The new system now operates as a fully closed loop chilled water circuit. By moving to a recirculating system Thornton & Ross significantly reduce water consumption and eliminate unnecessary wastewater, which improves environmental sustainability and reduces production cost.
Increased Operational Efficiency & Reduced Production Costs
The new chilled water infrastructure delivers more consistent flow and temperature stability across varying production loads. With modern pumps, improved filtration and refined process control, the system operates more efficiently than previous legacy equipment. These improvements help lower energy and water use, reduce maintenance demands and support Thornton & Ross’ wider sustainability goals.
Turnkey Project Delivery
Acting as EPCM contractor, Ai Process managed all aspects of the project including design, equipment procurement, installation, civil & electrical works, commissioning and documentation. All works were carefully phased around live pharmaceutical operations to avoid downtime or disruption. Through clear communication, coordinated contractor management and organized scheduling, the facility remained fully operational throughout the upgrade.
