Come learn about this project, a first of its kind in more than 30 years, combining state-of-the-art isolator, lyophilization, vial and syringe filling technologies to provide a flexible, robust and operationally efficient US source for generic pharmaceuticals.

This project, the first of its kind in more than 30 years, combines state-of-the-art isolator, lyophilization, vial, and syringe filling technologies to provide a flexible, robust, and operationally efficient US source for generic pharmaceuticals. The facility allows Nexus to expand upon its current product portfolio and offers an impressive array of product presentations, including aseptically filled and terminally sterilized liquid products in vial, syringe, and cartridge formats as well as lyophilized vials. 

The facility itself features several key facility of the future design elements, including multi-story construction, 2-story lyophilizer configuration, and the use of bridge trusses in key process areas. These design elements allow master planning for seamless expansion of manufacturing and packaging capacities and will facilitate future area manufacturing upgrades or re-purposing to ensure ongoing facility relevance. The aesthetically focused utility concept projects these modern design features and will be a welcome addition to the technology hub in Pleasant Prairie, Wisconsin.  

IPS is pleased to have been selected by Nexus to participate in this exciting project along with the equipment vendor partners featured on this tour – namely Bausch+Ströbel, Franz Ziel, IMA, and Optima. The high level of cooperation evident throughout the project resulted in innovative solutions to common design issues.
  
Phase 1 of this multi-phase, multi-year project, which features a barrier isolator-based liquid/lyo vial filling line is complete. Phase 2 of the project, which features a barrier isolator-based syringe filling line, is underway; full campus buildout is expected over the next 10 years. Attend this case study to hear details from Nexus, IPS, and our partnering vendors about project challenges and solutions.