Engineering flexibility.

Knee replacement surgery can provide patients with arthritis and chronic injury with tremendous pain relief, much greater mobility, and an enhanced quality of life. Traditionally though, orthopedic surgeons delayed joint replacement surgeries in patients under 65 because the materials used in the implants would not withstand normal wear for more than 10 to 15 years. But now, with the development by Smith & Nephew of oxinium femoral knee implants, younger, more active patients may benefit from knee replacement surgery. Made with oxidized zirconium, these implants are expected to reduce wear by up to 85%.

A unique manufacturing environment is required to properly handle oxidized zirconium in Smith & Nephew's patented process. In addition, clean rooms are necessary to ensure sterilization during final packaging of the product. Parts are decontaminated by moving through an acid bath in a process called passivation. From there, parts are sealed and boxed in clean rooms served by dedicated units with HEPA filters, reheat, and humidifiers.

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A 450-ton variable-flow chilled water system and a 2 MMBTU variable-flow hot water system serve variable-volume AHUs. Two 42,000 CFM AHUs serve the manufacturing space. Though upfront costs are higher, the use of chillers/water towers over HVAC equipment provides long-term savings in operating costs.

Meeting highly specialized design specifications was an ideal fit for the Pickering Facilities Team, selected to reconfigure a 105,000 SF warehouse for use in manufacturing the new knee implants.

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