In today’s pharma industry, where precision, hygiene, and efficiency are non-negotiable, pharma plant layout design and conveyor system design play a crucial role in determining operational success. From material transfer in cleanrooms to automated packaging lines, the complexity and criticality of conveyor systems in pharmaceutical facilities are increasing rapidly.

While popular engineering blogs highlight modern trends in conveyor automation, they often miss the deeper, structural, and detailing challenges that arise when integrating these systems into pharma plant layouts. That’s where Moldtek Engineering, a global leader in engineering services with 20+ years of project experience, delivers distinct value through precision-driven, tool-optimized, and cost-effective solutions.

In this article, we explore the engineering strategies behind effective conveyor system designs for pharmaceutical plants, examine layout best practices, and show where Moldtek’s structural steel detailing, BIM coordination, and mechanical design expertise change the game.

Why Conveyor Systems in Pharma Plants Demand Specialized Engineering

Unlike general manufacturing, pharmaceutical facilities demand strict standards in:

• Cleanliness and sanitation (adhering to cGMP and ISO standards)
• Contamination control (segregation of materials)
• Precision material flow (between formulation, packaging, and warehousing)
• Design integration with HVAC, cleanrooms, and fire safety systems

This creates a unique set of design considerations for conveyor systems:

Challenge	Strategic Design Requirement
Cross-contamination risk	Zoned conveyors with controlled material flow
Regulatory inspections	Compliant modular layouts with traceable material paths
Frequent cleaning	Hygienic stainless steel builds with accessible layouts
Downtime sensitivity	Predictive maintenance enablement, redundancy design

Moldtek specializes in designing conveyor-integrated systems using advanced tools like Tekla, Revit, SolidWorks, AutoCAD, and SDS/2, enabling seamless coordination with building structures, supports, mezzanines, and MEP layouts from the start.

Step-by-Step: Engineering a Conveyor System in Pharma Plant Layout Design

Successful implementation begins with understanding how conveyors interact with both the plant layout and regulatory workflow mandates. At Moldtek, our workflow for conveyor system design in pharma plants includes:

1. Initial Planning and Load Study

We evaluate:

• Product types and SKUs
• Batch volume and material flow frequencies
• Cleanroom classes per area
• Interfacing equipment (blisters, packers, sterilizers)

2. BIM Coordination and Digital Layouts

Using BIM coordination and 3D modeling via Revit and Tekla, we create a clash-free integration of:

• Conveyor supports, steel mezzanines
• HVAC ducting and HEPA filtration units
• Pipe racks and electrical raceways

Benefits:

• Pre-validated clearances
• Coordinated space utilization
• Early identification of interferences

3. Detailing Mezzanine Supports and Structural Integration

Pharma facilities often require elevated material movement to comply with process zoning. Our structural steel detailing services model every cross-beam, baseplate, and bracing to support:

• Overhead conveyors crossing sterile zones
• Suspended systems above clean corridors
• Load-bearing mezzanines for equipment

We deliver complete fabrication-ready shop drawings, connection detailing, and erection sequences ensuring faster and more accurate installation.

Conveyor Types and Strategic Use Cases in Pharma Facilities

Choosing the right type of conveyor is central to pharma plant layout effectiveness. At Moldtek, we help clients select and engineer solutions based on process stage and environmental compliance:

1. Modular Belt Conveyors for Primary Packaging

Application: Tablet sorting, vial movement, blister packaging
Key Features:

• Antimicrobial belts
• Modular plastic links for washdown areas
• Edge-driven to allow tight transfers

2. Cleanroom Roller Conveyors

Application: Material segregation between Class C and D zones
Design Considerations:

• Stainless-steel rollers
• Low-noise operation
• Minimal joints to reduce contamination risk

3. Vacuum and Pneumatic Conveyors

Application: Sterile powder and granule transfer in formulation areas

• Seamless integration with isolator-bound equipment
• Automation via PLCs and sensors

4. Overhead Monorail Systems

• Conceptually engineered to utilize vertical air space
• Best for cross-department transfer in constrained facilities

Moldtek’s mechanical designers use SolidWorks and AutoCAD to model these conveyors with real-world load simulations, ensuring both durability and process safety.

Pharma-Compliant Conveyor Design: Best Practices from the Field

Through thousands of engineering hours and pharma plant integration cases, we’ve compiled these core best practices for effective conveyor system design:

Clean Design Philosophy Checklist

•  Crevice-free joints to avoid residue
•  Use of food-grade materials (FDA/EHEDG)
•  Fully detachable belts and motors
•  Rounded frame corners

Functional Zoning for Material Movement

•  Segregation of raw, semi-finished, and packed goods
•  Airlock integration to prevent contamination
•  Controlled transitions between HVAC zones

Digital Engineering & Documentation

•  3D BIM models for site coordination
•  Fabrication-ready steel sections
•  Load and stress documentation for validation
•  Maintenance access strategy design

Integrating Conveyor Layouts into PEB Pharma Facilities

Many pharma plants today follow the Pre Engineered Building (PEB) approach for quick deployment. Moldtek is a pioneer in PEB detailing and engineering, and we bring that legacy into conveyor system planning.

Conveyor Integration in a PEB Environment

PEB Consideration	Conveyor Design Implication
Column grid spacing	Plan uninterrupted conveyor flow lines
Sloped roof frames	Allow overhead hooks and guide rails
Load carrying capacity	Reinforced beams under mezzanine systems

Moldtek’s integrated teams allow simultaneous structural and mechanical coordination, reducing the number of design loops and enabling early plant commissioning.

Future Trends in Conveyor System Design for Pharma Plants

The pressure to increase production efficiency, compliance, and traceability, will only increase. Conveyor system design is evolving quickly to meet these needs. Here’s what to watch:

Smart Conveyors with Real-Time Monitoring

• Motor torque sensors, belt slip detection, and predictive analytics
• Reduced unplanned downtime and increased OEE

Digital Twins

• Conveyor line modeling for performance simulations
• Virtual testing of layout scenarios

Hybrid AMR + Conveyor Systems

• Linking Autonomous Mobile Robots (AMRs) with static conveyors
• Dynamic material routing for personalized medicine manufacturing

Sustainable Materials and Energy Optimization

• Use of recycled polymers, energy-efficient servo systems
• Smart motor actuation only during demand cycles

Moldtek is actively investing in digital engineering, AI-driven design automation, and integration-ready mechanical modeling to drive next-gen pharma plant efficiencies.

Moldtek Engineering: Your Partner in Advanced Conveyor System Design

With over two decades of global engineering excellence, Moldtek empowers pharma and manufacturing companies by offering:

• End-to-end structural, mechanical, and BIM engineering services
• Tekla, Revit, AutoCAD, SolidWorks, and SDS/2 expertise
• Fabrication-friendly detailing and clash-free execution
• Fast turnaround, quality assurance, and cost savings

Whether you’re planning a greenfield pharma plant or retrofitting an existing facility, our multi-disciplinary teams add unmatched value in layout optimization, conveyor integration, and turnkey support.

Explore our structural detailing and conveyor integration solutions now to unlock smarter, faster commissioning for your next pharma project.