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GDP vaccine mega-warehouse (25,000 pallets) — India
Top-5 global vaccine manufacturer built a GDP + WHO PQ-compliant mega-warehouse serving domestic and UNICEF/GAVI export markets, including mRNA ULT storage.
Hyderabad, India 25,000 pallets · +2/+8 °C, −20 °C, −70 °C +2/+8 °C, −20 °C, −70 °C ULT
Challenge
- Zero-excursion mandate across +2/+8, −20 and −70 °C zones in one envelope.
- 45 °C summer ambient + monsoon humidity load on envelope.
- WHO PQ, GDP, 21 CFR Part 11 and CDSCO compliance in one validation programme.
ColdMatch solution
- Triple-loop refrigeration: chilled water for +2/+8 °C, NH₃/CO₂ for −20 °C, cascade ULT for −70 °C.
- N+2 chiller redundancy, dual-utility (grid + diesel + BESS) with 72h autonomy.
- 21 CFR Part 11 monitoring (2,400 wireless loggers), calibrated mapping ×3 seasons.
- ColdMatch coordinated EPC + ULT OEM + validation partner + WHO PQ audit prep.
Project scope
- Civil: 42,000 m² envelope, 350 mm PIR, vapour barrier, sub-floor heating.
- Mechanical: 6 MW chilled water plant, 2.8 MW NH₃/CO₂, 12× ULT cascade cabinets (−70 °C).
- Electrical: 12 MVA connection, 3 MW diesel N+1, 4 MWh BESS, dual MV feed.
- Automation: BMS, EMS (ISO 50001), 21 CFR Part 11 monitoring, SCADA + ERP integration.
- Validation: URS/DQ/IQ/OQ/PQ, seasonal mapping, WHO PQ + CDSCO audit dossiers.
Key engineering metrics
- Cooling load (total)
- 8.8 MW
- Specific energy
- 34 kWh/m³·yr
- Availability (validated)
- 99.997%
- Mapping deviations (Y1)
- 0
- Backup autonomy
- 72 h
- Refrigerant charge
- R1234ze + NH₃ low-charge + R170 (ULT)
weighted across 3 zones
ROI & financial performance
- Capex
- US$ 78M
- Annual savings
- US$ 9.4M/yr (vs distributed legacy sites)
- Payback
- 8.3 yrs
- IRR
- 13.6% (15-yr)
- NPV
- US$ 24M @ 10% WACC
- Energy reduction
- −29% vs distributed baseline
- CO₂ reduction
- −3,100 t CO₂e/yr
“Zero excursions in year one across three temperature zones. The validation programme cleared WHO PQ on the first submission.”
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