Large-Scale Manufacturing Facility Upgrade
A lean, integrated project delivery approach resulted in a 250,000sf world-class bulk biological production facility with an upgraded infrastructure and improvements in media, process and cell lines. The facility has received industry recognition for its exceptional design, innovative modular construction methods and strong safety record. Consisting of 22 subprojects with over 125 individual systems, the project was executed in 18 months with only a 4-month shutdown. The finished facility provided a 300% increase in yield over its previous production.
- Flexible manufacturing platform consistent cross-site
- Increased overall efficiencies with maximized throughput
- Consistency from early stage through commercial capabilities
- Increased titer capabilities from 1 g/L to >3g/L; 300% increase over previous capacity
- Increased capacity of de-bottlenecking and downstream process operations
- Implementation of new technologies enabled increased capacity for mixing media components
- Operations that perform with speed, excellence and discipline
- Avoidance of having to build new capacity to process higher yields
- Lean Project Delivery Methods utilizing BIM Technology design and modeled to within a ¼” tolerance
- Lean fabrication using modular skids and super skids to speed installation, improve quality and minimize environmental disruption
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