Leo Lynch HQ
16 Fonthill Industrial Park 
Fonthill Road North 
Clondalkin 
Dublin 22 
D22 P2T4 
Ireland

Munich, Germany
Fürstenrieder Strasse 5
80687 Munich
Germany

London, UK
20-22 Wenlock Road
London
United Kingdom
N1 7GU

Oxfordshire, UK
Harwell Innovation Centre
Harwell Science & Innovation Campus
173 Curie Avenue
Didcot
Oxfordshire
United Kingdom
OX11 0QG

Waterford, Ireland
2nd Floor
Block 6
Cleaboy Business Park
Waterford
Ireland
X91 FN73

© Copyright Leo Lynch 2024
Company registration number: 21901

Working 24/7 for 12 weeks, Leo Lynch helped Pfizer deliver a new flagship facility for the production of critical COVID-19 vaccination tablets. 

Exceptionally aggressive six-month fast-track project to support Pfizer in the fight against COVID-19

Project Lightspeed was a key project for Pfizer in the fight against COVID-19.  The facility produces COVID vaccination tablets, which can be stored at ambient temperatures for several weeks. Unlike injectable vaccines, they do not require specialist refrigeration.


“Lightspeed” was carried out as a fast-track project, with an exceptionally aggressive 6-month program. Construction ran 24/7 for a 12-week period. Leo Lynch worked with the design team early on to allow for installation of main piping runs. The facility was built as an extension of an existing cleanroom. This required detailed planning with production to ensure existing facility operations were not affected. The new cleanroom includes over 2,500 meters of process pipework in an existing plantroom. An external structure was built to house the dust collection equipment. Leo Lynch designed the project using BIM (LOD 400) with QAQC documentation located to our central EIDA platform.

Leo Lynch provided the coordination, supply, installation, testing and commissioning of all process, mechanical and HVAC services for a new OSD manufacturing suite.

Full services co-ordination for entire construction within a live pharma facility 

This project was carried out within a functioning pharma facility, spanning a clean room and live ATEX rated tank farm. It involved the construction of a Oral Solid Dose (OSD) manufacturing suite for Xeljanz production. It was built over 3 levels in the fallow spaces surrounding operational areas in Building 3C. Existing facilities included an operational cleanroom at ground floor level and plantroom on the top level with a functioning dust collector room. The new ground floor cleanroom includes powder charging and milling, blending, tablet compression, aqueous coating, solvent coating, coating solution prep, tablet drilling and printing rooms. The second floor included dust collection, purified water generation and mechanical plant rooms. Other areas were composed of Building 8, a solvent end of line abatement system and Area B6, an extension to the existing tank farm. Leo Lynch designed the project using BIM (LOD 400) with all of the QAQC documentation uploaded to our EIDA platform.

To ramp up production of a critical drug, Leo Lynch delivered a complete fit-out of a decommissioned area into new manufacturing suites. 

Process and HVAC precision, enabling Pfizer to produce nine billion tablets annually through its new production facility.

Delivered in distinct phases, the project involved the complete fit-out of the de-commissioned HT & LEVO areas of the site. The decommissioned areas were transformed into manufacturing suites comprising a cleanroom on the ground floor and two plantrooms above to house the project utilities. The production output of the new facility is 9 billion+ tablets annually.  


To achieve this volume, the facility required 4x twin tablet presses, 8x dust collectors, 4x compactors & tablet coaters, 2x blending machines, 4x post hoists (<8m) and 5x post hoists (9m). Leo Lynch was responsible for the offloading and installation of all large process and HVAC equipment on the project and running the utilities / process services to the equipment. The area was served by two AHUs: one to serve the plantrooms and the other to distribute air to the cleanroom. AHUs and all ductwork were installed and commissioned by Leo Lynch. 

Leo Lynch is the key mechanical contractor at Astellas Dublin, responsible for all small-to-medium mechanical installation projects on campus and managed by PM Group.

Go-to mechanical and process engineering partner for PM Group at Astellas Dublin. 

Leo Lynch has completed several HAZOP utility improvement projects including replacement of waste transfer lines, Ethanol, DMF, Toluene Flow meter Upgrade, P3 NaOH Replacement and N2 Purge system upgrade.  

Our team is currently engaged with PM Group and Astellas on a number of further HAZOP utility improvement projects including P2 HCl Line Replacement, P3 HCl addition project, Centrifuge improvement, Discharge Valve replacement, Tank Farm Outlet Automation, Tank Farm N2 Instrumentation and P3 Vacuum Pump replacement. 

The following projects are also in progress and due for completion in early 2024 - P2 Scrubber Replacement, P3 Glass Lined Vessel replacement, P3 Dryer removal, Air compressor replacement Vessel Bottom Outlet valves replacement, P3 Solvent filter replacement, P2 and P3 HVAC Upgrade, Brine Tank replacement.

Astellas Ireland

Project details

Related Projects