Noxell Cosmetic Manufacturing Facility

Fluor provided process design, site development and building design, procurement and construction management services for this grass-roots, 287,000-square-foot cosmetics manufacturing facility.

The project's site development included rail, truck and vehicular access, plus utilities, parking and landscaping. Specific site considerations included relocation of public utilities, development of a 95-foot span access bridge and environmental considerations for floodplain and erosion control.

Client's Challenge

The $22 million project included developing and designing manual and automated systems that produce Noxell's powder products, including face powder, blush and eye shadow. This new facility allows Noxell to manufacture products previously provided by contract suppliers.

Fluor's Solution

The total process involves material blending, storage, pressing and packaging under strictly controlled conditions of cleanliness and employee safety. Highly specialized dust collection and distribution equipment was required to prevent cross contamination of products while preventing exposure to employees. Blending equipment was designed for low probability of cross-product or microbial contamination, to provide the capability of being cleaned in-place and to allow flexibility of product mix.

The facility's powder production system includes automatic control of batch formulations, as well as an information system to report production results. Fluor also provided all of the software development and programming required to control the process.

Conclusion

The greenfield Noxell Cockeysville manufacturing plant is complete and operational.