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Projects

CGMP Biologics Pilot Plant

Teva Pharmaceuticals USA, Inc., West Chester, PA

Teva's facility is expected to run 3-5 campaigns a year, with each campaign lasting about 40 days (thaw through drug substance). Each campaign will produce anywhere from 2-5 kg in cell culture and will have the ability to utilize full or partial purification. In addition the facility was planned for a future fill-finish area. The facility will utilize primarily Single-Use Technologies to provide advantages in cost, operational flexibility, and reliability.

  • Design completed in Revit allowing for 3D project reviews throughout all phases of design
  • Site location evaluation 
  • Design of new clean utility generation and distribution including WFI, clean steam, clean compressed air, DI water, and nitrogen
  • Design of new central utility plant for facility including 2 – 100BHP boilers, 1 – 200 ton air-cooled chiller, 1 – 400 ton air-cooled chiller, 2 – desiccant dried rotary screw air compressors
  • Modular clean room system including Grade C and D with walkable ceiling for maintenance access

Cooperation among the designer, owner and construction manager allowed this $33.9-million project to reach substantial completion ahead of schedule and under budget despite converting a structure designed for commercial office and warehouse use into a manufacturing facility.

The seven-month project began by demolishing the existing building to a shell to avoid having to purchase new land. The building was reconstructed to house the classified manufacturing facility, adjoining areas and utilities. To achieve operational flows, the design team created a layout and co-located the utilities within the manufacturing space. The team says that creating ample space under a low single-story roof to accommodate tall process equipment was challenging. After removing existing utilities, the team ran many of the new utilities through the joists and also ran large ductwork to the roof.

Client Name: Teva Pharmaceuticals USA, Inc.
Region: AmericasCountry: United StatesOffice: Blue Bell, PA
Services: Architecture, Design, Engineering, Critical UtilitiesIndustry: Biotechnology & BiomanufacturingFacility Types: Research & Development, Manufacturing
Size: 38,000sfAwards: 2018 ENR MidAtlantic Best Project Award of Merit: Manufacturing
Client Name: Teva Pharmaceuticals USA, Inc.
Region: AmericasCountry: United StatesOffice: Blue Bell, PA
Services: Architecture, Design, Engineering, Critical UtilitiesIndustry: Biotechnology & BiomanufacturingFacility Types: Research & Development, Manufacturing
Size: 38,000sfAwards: 2018 ENR MidAtlantic Best Project Award of Merit: Manufacturing

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