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BIM, VR and AR in Pharmaceutical Design: Efficiency, Control and Integrated Quality

Techniconsult Group — Tue, 29 Jul 2025 09:39:58 +0000

The original language release (Italian) is the official and authorized version of the release. This translation is only a means of assistance and should be compared with the original language text, which is the only version of the text that will be legally valid.

It’s not an extra cost. It’s an added guarantee.

In the pharmaceutical sector, plant design is a highly complex challenge. Even a minor design error can lead to major consequences: project delays, regulatory non-compliance, additional costs, or—at worst—safety risks for personnel.
Designing facilities in compliance with GMP (Good Manufacturing Practices) requires absolute precision, coordination among multiple stakeholders, and a level of foresight that goes beyond traditional 2D drawings.
In this context, tools like Building Information Modeling (BIM), Virtual Reality (VR), and Augmented Reality (AR) now offer concrete solutions to these demands. These are not “tech accessories,” but operational tools already integrated into established workflows, delivering tangible benefits from the earliest stages of the project.

BIM: The solid foundation for everything

The first point to clarify is that without a well-structured BIM model, VR and AR cannot exist. BIM is not a software, but a methodology—a design approach that enables the creation of a 3D digital and data-rich model of the facility, where each element contains technical data, spatial relationships, and functional logic.
Thanks to BIM:
• All professionals involved (designers, engineers, clients, installers) work on a single, constantly updated model.
• Design issues can be anticipated early (clash detection, accessibility, ergonomics).
• The groundwork is laid for immersive technologies.

Virtual Reality for design review and training

Once the BIM model is created, it can be transformed into an immersive, navigable environment using Virtual Reality.
In pharmaceutical design, VR-based design reviews are especially effective for:
• Actively involving the client in the design process, even without technical expertise.
• Verifying operator workflows, access to utilities, and flow consistency (personnel/material).
• Gathering timely feedback before moving to the execution phase.

But VR goes further—it becomes a valuable tool for training personnel who will work in the production area: simulating complex operational procedures in a safe and realistic environment, optimizing timelines, demonstrating tasks during production downtime, and reducing the risk of errors once in the real environment.

Augmented Reality for construction and maintenance

At the same time, Augmented Reality finds direct application on-site and during quality control activities. By projecting the BIM model into the real environment via tablets or headsets, it’s possible to:
• Verify correct installation against the design.
• Compare real-time progress with the digital model.
• Support inspection and commissioning activities.

AR also proves useful post-construction, for maintenance or revamping operations. Technicians can access technical data simply by pointing their device at the relevant element—saving time searching for information and simplifying complex tasks, while reducing the risk of human error.

Not just for large companies: Accessible technology

One of the most common objections is that these technologies are reserved for large companies with big budgets. In reality, BIM-based design has been implemented in structured firms like ours for over 10 years, and is now fully integrated into our processes.
This means it doesn’t require additional effort or cost.
The initial investment quickly pays off through:
• Fewer design revisions.
• Reduced errors on-site.
• Optimized training and plant start-up.

A shift in mindset, not just technology

Adopting BIM, VR, and AR is not just about tools—it’s about a design culture. It means shifting focus from execution to foresight, from correction to anticipation, from “problem management” to “information management.”
In the pharmaceutical sector, where time is money and quality is a regulatory requirement, these tools are not optional—they’re a competitive advantage.

In collaboration with Giovanni Cuciniello, BIM Manager, and Andrea Daviddi, CDE Manager.

L'articolo BIM, VR and AR in Pharmaceutical Design: Efficiency, Control and Integrated Quality proviene da Techniconsult.

Designing with Computational Fluid Dynamics (CFD)

Vincenzo Montalto — Thu, 17 Jul 2025 07:52:20 +0000

Designing Pharmaceutical Warehouses with CFD

For over a decade, Techniconsult has been integrating Computational Fluid Dynamics (CFD) simulation into its engineering activities serving the Life Science sector. Thanks to advanced software tools, CFD makes it possible to simulate the thermo-fluid dynamic behavior of any type of ventilated system. This enables the design process to be guided and its outcomes anticipated, drastically reducing the risk of errors. In fact, this capability is becoming increasingly important, as the growing complexity of projects demands a combination of high-quality standards with the increasingly relevant issues of energy saving. It’s no coincidence that pharmaceutical warehouses—dedicated to the storage and distribution of drugs and related products—are fully part of this context.

For this reason, Techniconsult uses CFD simulation in the design, review, and optimization of various types of warehouses.
Given that this type of environment must ensure a significant internal volume and, generally, the vertical development that characterizes most of them, the most challenging issue to solve—whether in the design of a new building or in corrective interventions on an existing one—is to ensure adequate distribution of airflow and, therefore, good temperature uniformity within the space.

Designing New Buildings

CFD simulation can accurately anticipate thermal mapping and, consequently, the results of the Performance Qualification of a new warehouse already during the design phase.
In fact, it is possible to simulate the performance of the HVAC system under various external environmental conditions, evaluating different distribution layouts, airflow rates, and the thermo-hygrometric characteristics of the air, all based on the Client’s final objective.

For example, we can monitor the maintenance of a specific average temperature inside the building; the reduction of energy consumption by avoiding unnecessary oversizing; compliance with specific thermo-hygrometric conditions required to prevent product degradation; or adherence to specific requirements established by GMP regulations.

Finally, CFD software provides numerous tools for result analysis and various visualization modes, which are useful depending on the type of parameter—global or local—that is of greatest interest.

Iterative and Interactive Analysis of the HVAC System During the Design Phase.

CFD Simulations Performed Under Summer and Winter Design Conditions: Temperature Maps.

Layout 1 – Winter

Layout 2 – Winter

Evaluation of Thermo-Fluid Dynamic Performance Integrated into the Design Process, Aimed at Layout Optimization and Airflow Rate Definition.

Layout 1 – Summer

Layout 2 – Summer

Corrective Actions or Revamping of an Existing Building

In the case of corrective actions or revamping of an existing building, the main advantages of CFD—beyond those already mentioned for the design phase—include the ability to simulate and therefore closely study the current functioning of the building in all internal load configurations and under all operating modes of the dedicated HVAC system.

This makes it possible to thoroughly investigate the critical issues for which the Client is requesting a corrective intervention (which may be related to the system or the building structure) and to propose targeted solutions aimed at eliminating or reducing these issues.
Subsequently, CFD simulation allows for the proposed solutions to be validated in advance and, if required by the building-system configuration (or even by the Client), enables the division of the solutions by intervention area and the planning of their implementation in successive phases.

Request for HVAC Revamping Following the Detection of Frequent Temperature Sensor Out-of-Range Events.

CFD simulation highlighted a serious problem of thermal stratification in the vertical development of the warehouse.

Layout 1 – Before the modification

Layout 2 – Before the modification

The design solution adopted led to a significant reduction of the temperature gradient and an improvement in the uniformity of air distribution.

Layout 1 – After the modification

Layout 2 – After the modification

L'articolo Designing with Computational Fluid Dynamics (CFD) proviene da Techniconsult.

AI and BIM design: a new era for architecture and engineering

Anna Corsi — Thu, 13 Feb 2025 07:57:21 +0000

In recent years, technology has profoundly transformed many sectors, and the world of architecture and engineering is no exception. One of the most promising innovations is the integration of Artificial Intelligence (AI) into Building Information Modeling (BIM) processes. This combination not only increases efficiency but also opens up new possibilities for more advanced and sustainable design. But how can AI concretely improve the BIM design process?

Automation and Simulations: How AI is Revolutionizing BIM Design
AI brings with it the promise of automating many repetitive tasks, an aspect that often slows down the work of designers. For example, creating three-dimensional models or parametric families: processes that require hours of work can be sped up thanks to AI tools capable of generating 3D models from two-dimensional drawings or laser scanner surveys. This automation allows professionals to devote more time to critical and innovative decisions, thus improving the quality of work.

Today, there are numerous tools that, when used with AI support, help and improve the performance of three-dimensional projects in modeling, coordination, and management. Among the most widely used software in BIM, we find tools like Revit and Navisworks, which are complemented by AI-related tools. Revit, developed by Autodesk, is already known for its advanced parametric design features, but with the integration of AI tools like Spacemaker, it is possible to automate simulations to study the impact of variables such as natural lighting, acoustics, and airflow, and to suggest optimized design configurations, which is very useful for assessing the feasibility of a project. These tools help predict how the project will interact with the surrounding context, supporting the design process and allowing for more targeted and informed responses to real needs. Other tools applicable to these processes include Hypar, Archistar, TestFit, and Zebra.

Model Optimization: Design, Efficiency, and Coordination
In addition to simplifying repetitive tasks, AI stands out for its ability to optimize the design itself. Machine learning algorithms can analyze vast amounts of data from previous projects and suggest effective solutions, ranging from more functional layouts to materials that improve the building’s energy efficiency to coordinating the model with other disciplines. This type of support can be crucial in the various stages of a project, where small improvements can translate into significant benefits in terms of cost and time savings. In this context, tools like BIMcollab with AI-assisted clash detection or Verifi3D offer specific functionalities for model management and control. BIMcollab is primarily a clash management and coordination tool, ideal for team members who need to coordinate and resolve clashes collaboratively. Verifi3D, on the other hand, focuses on overall model verification and compliance, making it particularly useful for those seeking a model verification and quality control tool. Other tools that can support these activities include Solibri AI, Revizto AI Assist, and ClearEdge3D Verity.

Smart Monitoring: From Prevention to Real-Time Management
Another area where AI proves fundamental is predictive analysis. AI-integrated BIM software can identify potential problems before they occur. Imagine a construction site where HVAC, electrical, and plumbing systems must coexist without interference. AI can detect potential conflicts and suggest corrections, thus avoiding costly delays and adjustments during construction. For example, a construction site where drones and cameras constantly monitor work progress, collecting images and videos that AI analyzes in real-time. This allows comparing current progress with the planned schedule and immediately identifying any discrepancies in time and costs, providing Project Managers with the tools to make more informed decisions based on solid forecasts.

Simulations and Smart Planning
AI also makes advanced simulations and “what-if” scenarios possible. Before committing significant resources to a project, teams can test different design options and see how they would perform under real conditions. This ability to predict the impact of decisions allows for more agile and adaptable design, improving risk management and increasing the chances of success.

Towards a New Design Model
Despite the numerous promises, the adoption of AI in BIM design still presents challenges. Data management, the need for continuous updates, and the training of professionals are just some of the issues to be addressed. However, the potential of AI to improve the quality, efficiency, and performance of projects is undeniable. In conclusion, the integration of AI into BIM design represents a revolution that pushes the sector towards a more digital and intelligent future. Those who can embrace this synergy will have the opportunity to create more innovative, efficient, and sustainable projects, paving the way for a new way of conceiving architecture and engineering.

And you, are you ready to embrace this transformation that will simplify the rules of the game and enrich us with new possibilities?

L'articolo AI and BIM design: a new era for architecture and engineering proviene da Techniconsult.

Advantages of computational fluid dynamics (CFD)

Lapo Galligani — Wed, 28 Feb 2024 15:46:31 +0000

Nowadays, issues related to the study of fluid dynamics are becoming increasingly frequent and particularly impactful on the successful outcome of a project. It is in this scenario that Computational Fluid Dynamics (CFD) has increasingly taken on a leading role, driven by the need to achieve high levels of confidence in what we design.

Computational Fluid Dynamics (CFD) is a branch of engineering and physics that deals with the study and simulation of fluid flows (liquids and gases) using numerical methods and computational algorithms. Specifically, CFD focuses on analyzing the behaviors of moving fluids, encompassing phenomena such as turbulent, transient, or steady flows, heat exchange, and chemical reactions. It enables the optimization of product designs, prediction of device and structure performance, improvement of energy efficiency, and analysis of complex processes without the need for costly experimental tests.

The increasing accessibility and cost-effectiveness of significant computing power have turned numerical simulation into a current and efficient tool, with increasingly shorter waiting times to obtain results.

In the current landscape, numerical simulation, and hence CFD, consistently complements and in some cases guides the traditional experimental method, offering advantages in terms of time and cost while reducing the number of cases to test, although not replacing it entirely.

Techniconsult has gained considerable experience in using the CFD tool, applying it in numerous contexts involving the study and understanding of fluid dynamic phenomena:

Fluid dynamic analysis of pharmaceutical premises;
Fluid dynamic analysis of pharmaceutical production machinery;
Fluid dynamic analysis of mixing/fermentation tanks;
Thermo-fluid dynamic analysis of temperature-controlled warehouses;
Design and optimization of air diffusers.

In our experience, the use of CFD has proven to be a key factor both as a guide for new designs and as a detailed analysis tool for existing issues. In the case of the pharmaceutical industry, we can cite instances of failed smoke tests or environmental contamination issues.

Want to learn more? Keep in touch! We will provide practical examples demonstrating how this tool can drastically simplify the phases of design and troubleshooting, as well as authorization processes.

L'articolo Advantages of computational fluid dynamics (CFD) proviene da Techniconsult.

The contribution of CFD simulation to sustainability in the pharmaceutical industry

Pier Angelo Galligani — Thu, 28 Sep 2023 15:54:25 +0000

In the pharmaceutical industry, adoption of contamination control strategies (CCS) and the implementation of adequate quality risk management measures (QRM) are critical for organizations to guarantee product quality and safety. Computational fluid dynamics (CFD) simulation has emerged as a powerful tool to provide invaluable insights into fluid flow, heat transfer, contamination dispersion and control within the manufacturing environment.

Today, alongside GMP compliance, optimizing energy consumption and reducing the carbon footprint have become significant concerns due to the substantial ventilation airflows required for clean spaces and classified environments. By leveraging CFD simulation in HVAC design, pharmaceutical organizations can support contamination control strategies (CCS) as well as implement robust quality risk management practices, ultimately ensuring the production of safe and effective pharmaceutical products while driving sustainability initiatives.

How CFD simulation can support Contamination Control Strategy (CCS) and Quality Risk Management (QRM)

Controlling contamination is of paramount importance in pharmaceutical plants to ensure product quality, safety, and compliance with regulatory standards. CFD simulation plays a pivotal role in supporting CCS and QRM by providing a comprehensive understanding of airflow patterns, particle dispersion, and the expected performance of cleanrooms. Through accurate modeling, CFD simulation helps identify potential contamination sources, evaluate the effectiveness of ventilation systems, and assess the system’s capability to respond to possible contamination events. By visualizing airflow patterns and particle trajectories, areas with inadequate performance can be identified, leading to the implementation of targeted mitigation strategies to minimize contamination risks. Moreover, CFD simulation aids in optimizing air filtration systems, cleanroom layouts, and operational procedures to enhance overall contamination control measures.

How CFD simulation can support sustainability initiatives

Computational Fluid Dynamics (CFD) simulation offers significant advantages in optimizing airflow design and associated energy consumption in classified areas within pharmaceutical plants. By accurately modeling and analyzing the airflow, CFD allows for the reduction of energy-intensive processes while ensuring operational efficiency, thus contributing to sustainability efforts.

Reducing Energy Consumption in Classified Areas at the design condition:

CFD simulation enables the optimization of design airflow rates in classified areas, leading to substantial reductions in energy consumption associated with ventilation systems. By fine-tuning the design airflow rates, pharmaceutical plants can ensure that the necessary cleanroom conditions are maintained while minimizing unnecessary energy expenditure; this results in cost savings and reduced environmental impact.

Supporting programs for Energy Savings in non-operational periods:

Thanks to simulation process, CFD can assist in the implementation of energy-saving programs by evaluating and reducing airflow rates during non-operational and unmanned periods. In unmanned conditions, HVAC systems for classified areas can maintain required performance levels with reduced airflow rates. CFD simulation aids in anticipating the performances of HVAC systems at reduced airflow conditions, identifying areas with inadequate performance, and enabling corrective actions early at the design phase.

Reduction of ventilation energy burden:

The energy consumption for ventilation is proportional to the cube of the supplied air volume. Consequently, even limited reductions in airflow rates can lead to a substantial decrease in energy consumption for ventilation systems. Reducing ventilation contributes to economic savings but also positively impacts the overall energy consumption of utilities production systems.

Enhancing Sustainability through CFD:

By leveraging CFD simulation, pharmaceutical companies can proactively pursue sustainability goals. Optimizing airflow rates and implementing energy-saving programs aligns with environmental commitments and reduces the plant’s carbon footprint. Additionally, reduced energy consumption contributes to overall sustainability by conserving natural resources and decreasing greenhouse gas emissions.

Figure N.1 – Example
Use of CFD for the optimisation of airflow patterns in a “grade B” filling room. Case description

Problem: high quantity of air coming from the RABS and the HEPA ceiling to be returned to the HVAC system -> preliminary CFD analysis of airflow patterns inside the room -> difficulty to balance the system, risk of eddies.
Solution: Corrective actions and optimization of flows via the introduction of an additional air-wall and the sectorizing of two air-walls -> virtual balancing of the return airflow rates.

Results of CFD simulation

In general: airflow patterns after corrective actions are more even. Eddies shown in the section are eliminated and unidirectionality of air flow is much more present in the room space -> risk of back flow from floor level to critical areas (staging areas, open RABS outlets and mouse-hole) is reduced.
At the same time, this aerodynamic correction can support the reduction of room airflow rate during at rest conditions

Conclusion

CFD simulation has emerged as a powerful tool to support contamination control strategies, quality risk management, and sustainability initiatives in pharmaceutical plants. By accurately predicting fluid flow, heat transfer and contamination dispersion, CFD simulation enables organizations to make informed decisions, optimize processes, and ensure the production of safe and effective pharmaceutical products.

L'articolo The contribution of CFD simulation to sustainability in the pharmaceutical industry proviene da Techniconsult.