Hello, future! A factory to revolutionize intraocular lens production
GSE completed the construction of a new factory for ZEISS in Périgny, near La Rochelle. The 14,300 m² facility is dedicated to the manufacture of medical devices, in particular intraocular lenses (IOLs) for the treatment of cataracts. This project is an essential step to increase ZEISS’s production capacity, fully integrating the Industry 4.0 principles of process automation and digitisation.
Many partners participated in the project, aligned on the objectives of performance, quality and client satisfaction. The factory will considerably increase production, while enabling the development of new products and the implementation of automated production lines. All of this is part of a more environmentally friendly approach.
About the site
The extension of the existing site added a 13,897 m² building, including 2,000 m² of offices fitted out by GSE’s Design team. These new spaces will enable the development of new products, in an environment that is more respectful of the ecosystem and fosters user wellbeing. Due to the site’s limited size, we designed a four-storey building, two of which are dedicated to production.
We used Building Information Modeling (BIM) to design the project. The 3D digital model makes it possible to visualise the project and plan the construction work in great detail, reducing costs and saving time both in the design phase and during the works.
About the architecture
The architects designed a modern and refined building. They gave particular attention to the street-facing façade: large vertical sunshades enliven it and give it depth. The offices are located behind it. The ground level houses the new entrance and the company restaurant, and screens the logistics yard from the street. Further back is the site’s production area.
The new facility meets the requirements of flexibility and efficiency, optimising workflows and anticipating future developments.
About sustainability
Energy performance
The project’s environmental ambitions are reflected in the high performance of the building envelope and the frugality of the technical systems, aligned with the investor’s green building strategy. A preliminary survey identified and analysed several technical solutions that met the client’s requirements regarding investment, operating costs and environmental performance. The goal: to create a building that goes beyond regulatory requirements in terms of energy performance.
To maximise frugality, the following choices were made:
- Produce renewable electricity at a rooftop solar plant of approximately 483 kWp.
- Recover waste heat from the process, covering up to 21% to the offices’ heating needs.
- Commission technical systems and contribute to energy efficiency.
- Recover energy thanks to the interconnection of the air handling units (AHUs), the heat pump and the compressed air system.
Low-impact worksite
The project aimed to minimise the works’ environmental impacts. To this end, a rigorous environmental monitoring system was set up, based on a clean worksite code that required all contractors on site to comply with strict environmental standards. Particular attention was paid to waste recovery. Indeed, the project exceeded EU targets for the construction sector, with an overall recovery rate of over 85%. In addition, an area was set up for the recovery of surplus construction materials: 850 kg of materials were donated for reuse in future construction projects. This approach reflects the project’s commitment to sustainable development and to reducing its environmental footprint.
Biodiversity in harmony
The project’s landscaping promotes biodiversity. To protect local species, we followed the recommendations of Birdlife France (Ligue pour la Protection des Oiseaux), Biotope and GSE’s own environmental engineer, which included alternative habitats such as hedges, vegetated ponds, a flower meadow and trees adapted to the climate. In addition, timer-operated indirect lighting was installed to limit light pollution, providing an environment that is respectful of the wildlife. These initiatives demonstrate a strong commitment to the protection and promotion of biodiversity on the site.
“This is a major milestone. The building was delivered on time, thanks to the collaboration of the ZEISS and GSE teams. Well done, everyone!” Gildas Lorec, Operations Director & Site Manager, Zeiss.
