Manufacturing & Industrial


Developing innovative, energy efficient facilities to maximise potential and minimise footprints.

RPS designs manufacturing facilities that are compliant, safe, efficient and cost effective. We have a proven track record in all phases of project execution, from site selection and utilisation studies, through concept and feasibility, to detailed design, construction supervision and facility handover. Our services range from the design of new buildings and facilities to the refurbishment or expansion of existing process operations within a live plant environment.

Our sustainable designs are simple in concept, economic to construct and cost effective to maintain, with inherent flexibility to accommodate changing process requirements. Our integrated, multi-disciplinary teams are highly skilled at coordinating the crucial interfaces between the process equipment, the building layout and structure, and the building services to maximise development potential.

We have provided a range of services on major facilities in the pharmaceuticals, food processing, medical technologies and advanced manufacturing sectors.

Case Studies

Allergan Pharmaceuticals

Allergan Pharmaceuticals Allergan Pharmaceuticals


RPS has been engaged in a programme of continuous capital expenditure over a number of years to develop all aspects of the Allergan facility in Westport, Co. Mayo.

Allergan is global specialty pharmaceutical company that develops and commercialises innovative products for the ophthalmology, neurosciences, medical dermatology, medical aesthetics and other speciality markets. Their facility in Westport, Co. Mayo was established in 1977 and has grown to over 500,000 sq. /ft. on a 30 acre campus and includes state-of-the-art chemistry, microbiology and stability laboratories. Manufacturing operations include automated pharmaceutical and biologic filling and packaging lines.

RPS is engaged on a substantial manufacturing expansion, to construct a new Vial Fill Finish Facility with project costs for this phase in excess of €120m. RPS design, engineer and specify the mechanical, HVAC, process equipment and clean utilities for all aspects of the site. We also assisted Allergan with environmental aspects on the site.

Forest Laboratories

Forest Laboratories Forest Laboratories

Forest Laboratories Ltd.

RPS has been engaged in a programme of continuous capital expenditure over a number of years to develop all aspects of the Forest Laboratories facility.

RPS design, engineer and specify the mechanical, HVAC, process equipment and clean utilities for all aspects of the site. RPS has been involved in numerous projects in two plant buildings, including a tabletting facility, production area expansion, cold rooms and a new warehouse facility.

RPS has also provided specialist environmental advice and support to Forest Laboratories. In February 2011, RPS submitted an Integrated Pollution Prevention Control (IPPC) Licence to the Environmental Protection Agency (EPA) on behalf of Forest Laboratories. The IPPC licence was successfully granted by the EPA and we have continued to advise on the implementation of the licence conditions.

Our team has carried out a hydrogeological site investigation, firewater risk assessment, environmental liabilities risk assessment (ELRA), a decommissioning management plan (DMP), as well as providing annual noise monitoring, bi-annual groundwater monitoring, and ongoing environmental support and advice to senior management.

Masterplanning for Diageo

Masterplanning for Diageo Masterplanning for Diageo


RPS has provided professional town planning services to Diageo Ireland for many years.

Recently, our work for Diageo included preparation of a masterplan for the redevelopment of part of the St. James’s Gate Guinness Brewery facility in Dublin. The proposed redevelopment includes a new brew house constructed on the northern campus of the 55-acre site.

RPS assisted Diageo in securing planning permission for the proposed brew house development from Dublin City Council. This involved successfully negotiating amendments to the Dublin City Development Plan. The new brew house represents a major element of Diageo’s new multi-million euro redevelopment project for the landmark St. James’s Gate Brewery.

Mylan Sterile Fill Finish Facility

Mylan Sterile Fill Finish Facility


RPS has been engaged with Mylan on a number of programmes to upgrade the Bioniche Pharma facility in Co. Galway.

Bioniche Pharma (now part of Mylan) is a global manufacturer of injectable pharmaceutical products serving a variety of niche markets, with expertise in aseptic fill finish processing.

The upgrade works at Bioniche Pharma at Inverin, Galway required pharmaceutical manufacture and vial and syringe packaging lines. RPS has been engaged in a number of programmes of capital expenditure over a number of years to develop the facility. To date, we have completed a full upgrade of a manufacturing area and a substantial manufacturing expansion plan and full design to construct a new Vial and Syringe Fill Finish Facility.

RPS responsibilities included:

Site Masterplanning

Project Management

Mechanical, Electrical and Process Design

Cleanroom Design

Civil, Structural & Architectural

Environmental & Wastewater Treatment


PepsiCo Worldwide Flavours (PWF) – Evolve 2.0

PepsiCo Worldwide Flavour PepsiCo Worldwide Flavours (PWF) – Evolve 2.0

PepsiCo Worldwide Flavours (PWF)

RPS is providing project management and full multidisciplinary design services for a new food powder blending facility for PWF in Cork.

The new facility is a standalone production plant incorporating 4,000m2 of floor space. The facility comprises a relative humidity controlled clean manufacturing facility, an ambient warehouse, utility space and support functions such as administration, amenities and laboratories.

The process equipment specification, procurement, installation and hook up are all within the RPS scope. The building is being designed and constructed to incorporate the requirements for Leadership in Energy and Environmental Design (LEED) Sustainability Assessment.

Spent Catalyst Waste Assessment

Spent Catalyst Waste Assessment

Novartis Ringaskiddy Ltd.

RPS was appointed by Novartis to carry out an assessment of spent catalyst waste arising from the production of a particular pharmaceutical product, to determine if the waste could be classified as hazardous or non-hazardous.

The spent catalyst waste stream was classified using the EPA's “Paper Tool of the Procedure for the Identification of the Hazardous Components of Waste”, Volume I (Clean Technology Centre, August 2004).

RPS was responsible for the interpretation of the laboratory results, the classification of the waste using the EPA's paper tool and preparation of a final report outlining the sampling procedure, laboratory analysis and classification of the spent catalyst waste for submission to the EPA. The final report has been submitted to the EPA for comment. Similar work for the classification of bottom ash and slag from the solid waste incinerator is ongoing.