Pharmaceutical Plant Expansion

Kroeschell was tasked with a functional update of Flex's state-of-the-art medical manufacturing facility.

About this project

Turnkey design/build mechanical, electrical, and general trades contract to upgrade and expand existing manufacturing plant to produce a new FDA-approved medical device.

Kroeschell saved the customer $3 million through value engineering over the course of the project.


The FLEX LTD Manufacturing Facility located in Buffalo Grove, IL, was granted an FDA regulated mission critical contract to update their
facility and expand production lines within an 18-month timeframe. The project approach was both as a functional expansion of the
manufacturing plant as well as a case study to showcase future prospective clients the customer’s capabilities. After a competitive bidding
process Kroeschell was awarded the $21.6 million dollar fast-paced project.


Kroeschell developed the in-house design for the Mechanical, Electrical, Plumbing and Building Management Systems and acted as the
general contractor to construct all MEP trades and manage subcontractors in all other required trades to complete the turn-key project

New and Expanded Mechanical Systems:

  • (26,000’) Pipe installed involving chilled and condenser water,
    compressed air, nitrogen, vacuum, natural gas, and refrigerant
  • (1,000’) Underground plant sanitary plumbing expansion and
    manufacturing support plumbing.
  • (6) New rooftop units worth 2,000 tons of cooling installed on
    above the roof structural framing.

Interior buildouts for Microbiology Lab, QC Lab, and Vacuum Pump Room. Refurbished existing Clean Room including construction of new airlock and (62) fan HEPA Filters

Expanded Electrical Services:

  • (2) New Interior and (1) New Exterior 4,000 Amp, 277/480 Volt
    Electrical Services.
  • (670’) of 2,000 Amp, 480 Volt Buss Duct with (67) 400 Amp
    Bus Plugs.
  • (70) Transformers 480 to 400 Volt & 480 to 208 Volt Type
    serving (103)
  • New Panels.
  • Installation of over 100 miles of wire.

Building Management System installation encompassing HVAC
and plant controls, energy management, metering & analysis, lighting controls and full system integration including two satellite sites.



Kroeschell exceeded expectations by surpassing all project milestones and saving the customer $3 million dollars over the course of the project. All of this was accomplished with no downtime experienced by any of the other manufacturing lines that remained in operation during construction.

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