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Lupin Project Wins ENR Global Best Project Award of Merit: Manufacturing

Jul 11, 2019

ENR’s Global Best Projects identifies and honors the project teams behind outstanding design and construction efforts of the past year. They received a record number of entries produces a diverse set of projects located in 20 countries that focused on safety performance, innovations, challenges, and design and construction quality - with a special emphasis on the diversity of global project teams and their collaboration. They also considered how the project benefits the local community and/or the construction industry. Lupin was selected as an outstanding example that shows the risks, rewards, and hurdles overcome when designing and building internationally.

The mission of this project was to create an integrated large-scale pharmaceutical manufacturing facility for Oral Solid Dosage (OSD) and injectable products with state-of-the-art process equipment technology that achieved the highest level of sustainability and operational excellence. This sustainable, unique, and technically complex project sets a quality standard and template for how future projects in India should be executed and constructed to compete in the global market place.

The OSD manufacturing facility has fully automated storage and retrieval systems (ASRS) for handling work in process and change parts, such as dies and punches with RFID code identification to eliminate human errors and mix-ups to ensure the highest degree of accuracy and productivity.

The aseptic injectable manufacturing facility is designed to produce high potent compounds with multiple deliveries methods through different devices including liquid vials, lyophilized vials, cartridges, and pre-filled syringes. It is equipped with filling lines capable of producing millions of vials, pre-filled syringes and lyophilized vials per year. These lines are integrated with a fully contained isolator system.

The project incorporated good design practices, and the latest environmentally sustainable design features, and novel execution approaches that help the project stand out among the other projects in the Indian region. The project execution resulted in an excellent facility integration designed to reduce environmental impact. 

This project embodies the ideals of an ENR Global Best Project award because of the project leadership, coordination, and more importantly, the alignment across all global parties. The team benefitted from a details project execution approach and various synergies that supported a mutual working relationship. It demonstrates how integrating the industry’s best people with the right technology and energizing them with the right motivation produces a successfully implemented project.

All parties collaborated on the customized equipment design to optimize space utilization. Each provided input to the project schedule and brought their full organizational resources to deliver novel technology with a flexible design to the ready-to-use components for the syringes and cartridges. The customized design created the distinct benefit of eliminating costs associated with washing and depyrogenation operations.

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