Biogen has established a company-wide initiative to upgrade their facilities to increase their ability to handle more mature, high titer processes being developed internally. The LSM Facility Upgrades consisted of multiple sub-projects intended to extend the capabilities, flexibility and throughput of the facility.

The project involved major modifications to the cell culture, harvest and purification areas. The finished facility has provided a 300% increase in yield over its previous production output, effectively avoiding investment in new facilities at a substantial cost. These investments have yielded improvements in media, process and cell-lines. The improvements have significantly increased product yields.

• Flexible manufacturing platform consistent cross-site
• Increased overall efficiencies with maximized throughput
• Consistency from early stage through commercial capabilities
• Increased titer capabilities from 1g/L to >3g/L; 300% increase over previous capacity
• Platforms that facilitate and grow partnerships/collaborations
• Increased capacity of de-bottlenecking and downstream process
• Implementation of new technologies enabled increased capacity for mixing media components
• Operations that perform with speed, excellence and discipline
• Avoidance of building 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
• Project executed in 18 months with only a 4-month shutdown