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Projects

Large-Scale Biologic Manufacturing Facility Upgrade

Biogen Idec, Research Triangle Park, NC

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
Client Name: Biogen Idec
Region: AmericasCountry: United StatesOffice: Somerset, NJ
Service: Construction ManagementIndustry: Biotechnology & BiomanufacturingFacility Type: Manufacturing
Size: 250,000sf.Awards: 2010 ISPE Facility of the Year Award for Operational Excellence
Client Name: Biogen Idec
Region: AmericasCountry: United StatesOffice: Somerset, NJ
Service: Construction ManagementIndustry: Biotechnology & BiomanufacturingFacility Type: Manufacturing
Size: 250,000sf.Awards: 2010 ISPE Facility of the Year Award for Operational Excellence

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