Everyone in engineering knows the story: a project that starts with “Just copy the existing system” rarely stays that simple.

In this case, the reference system was more than a decade old. The documentation package was incomplete, several details were undefined, and many components were no longer current or compliant with modern site standards. Once we moved into detailed design, the gaps became obvious: instruments, valves, fittings, supports, and interfaces – far more than the original material list suggested.

But the shutdown window for installation was already fixed and non-negotiable.

So instead of treating it like a copy job, we approached it like a full engineering and fabrication project.

We rebuilt the design from the ground up: updated the P&ID, re-specified all critical components, resolved open points with the client, and refined the 3D model until every connection point, orientation, and clearance was settled.

For the vessels, we partnered with Roto Inox, whose experience and consistency ensured the mechanical and hygienic design met all requirements.

The systems were fabricated, assembled, and tested in-house so that installation time during shutdown would be focused on integration – not troubleshooting. All variations and late clarifications were handled transparently, with clear discussion of impact, options, and decisions.

The result?

Three modernised, fully engineered bioreactor systems aligned with current standards and ready for installation during the fixed shutdown slot – without shifting the date by a single day.

This is how we like to work: agile, transparent, and partner-first. We adapt when the scope evolves, but we stay disciplined on quality, clarity, and client intent. Because even when a project is called a “copy,” what the client truly needs is a system that works – not one that merely looks the same.

• Request to reproduce an existing bioreactor system
• Legacy design package with gaps and outdated components
• Critical shutdown installation window fixed months in advance
• Original documentation does not reflect current standards or site needs

• Full re-engineering of P&ID, specifications, and component selections
• Fabrication and assembly of three new bioreactor systems
• Redesign of process, mechanical, and layout details
• Collaboration with proven vessel partner Roto Inox

Even a “copy” requires full engineering discipline – nothing is ever truly one-to-one.