When a pharmaceutical manufacturer needed to quickly expand one of its blow-fill-seal production lines, Coward Environmental Systems, Inc. (CESI) stepped in to help, delivering a cleanroom air filtration solution in record time. Working with AJ Manufacturing, CESI supplied expedited terminal HEPA filter units that were designed, built, and delivered in just two weeks, a fraction of the industry’s typical lead time.
Supporting a Critical Expansion
The project involved the installation of new blow-fill-seal equipment, a highly specialized system used to produce sterile, single-dose injectable products.
“Blow-fill-seal is a fascinating process,” explained Greg Munter, PE, Partner and Sales Engineer at CESI. “The machine actually forms the small plastic vial, fills it with the medication, and seals it — all in one integrated process — without anyone ever having to touch the product. It’s completely automated and incredibly clean.”
To maintain the sterile environment around this critical machinery, the client required a series of terminal HEPA filters capable of removing airborne contaminants and sustaining the cleanroom classification around the production area.
Delivering Cleanroom Filtration Fast
Under normal circumstances, terminal HEPA units have a six-to-eight-week manufacturing lead time. But the client’s expansion timeline required a much faster turnaround.
“They needed the filters and housings right away, not in two months,” said Munter. “We worked closely with AJ Manufacturing to expedite production and had the terminal HEPA units delivered in about two weeks.”
That rapid response allowed the client to stay on schedule for a major equipment installation milestone.
Engineered for Pharmaceutical Cleanrooms
Each unit supplied by AJ Manufacturing consisted of a stainless steel terminal HEPA housing, which mounts in the ceiling and allows air to pass through high-efficiency particulate filters before entering the cleanroom.
“The terminal HEPA is basically a stainless steel box in the ceiling that holds a HEPA filter,” Munter explained. “All of the supply air passes through that filter before entering the room, ensuring it meets the cleanroom air quality standards required for pharmaceutical manufacturing.”
The units were installed directly above the blow-fill-seal equipment, maintaining strict control over temperature, humidity, and particulate levels in the area. The configuration supports the Good Manufacturing Practice (GMP) requirements that govern all sterile pharmaceutical production environments.
Fast Turnaround, Reliable Performance
While the expedited shipment involved only a dozen filters for this phase of the project, CESI and AJ Manufacturing have supported multiple stages of the client’s facility expansion.
“Even though it wasn’t a large volume order, the timing was critical,” said Munter. “We were able to coordinate with AJ to make it happen quickly. Their ability to expedite manufacturing made all the difference.”
Collaboration That Keeps Projects Moving
The success of the project highlights CESI’s ongoing role in helping pharmaceutical manufacturers achieve compliance and efficiency, even under tight schedules.
“At CESI, we focus on being a resource our clients can depend on — especially when timing is everything,” Munter said. “By working closely with trusted partners like AJ Manufacturing, we can respond fast, maintain quality, and help our clients keep production moving.”
About Coward Environmental Systems, Inc.
CESI represents premier HVAC and environmental control manufacturers across the Mid-Atlantic region, providing engineering expertise, product solutions, and technical support for commercial, industrial, and institutional clients. With a strong focus on critical environments such as cleanrooms and laboratories, CESI helps ensure comfort, compliance, and performance through high-quality, engineered systems. To learn more, contact us today.
