This biopharmaceutical design-build manufacturing project included the deconstruction of seven specific manufacturing areas totaling over 100,000 sq. ft. The scope included rebuilding the seed train bioreactor suite with the inclusion of N-1 perfusion equipment, reducing equipment downtime through the debottlenecking of CIP distribution and the addition of a new CIP skid, implementation of new process analytics to reduce process sampling requirements, and additional harvest capacity to handle the increase in cell mass. 

The re-construction effort resulted in procurement and the installation of nine new vessels, 14 process skids, more than 1,000 sanitary diaphragm valves, and 1,500 process instruments. This effort was completed within a three-month shutdown schedule that also include time for commissioning services. Declared the largest shutdown Biogen has ever undertaken within an existing facility, detailed collaboration and planning from DPR, CRB, IPS and all Trade Partners occurred starting 18 months before day one of the shutdown. The collaboration resulted in a design which was phased to allow early release of the long lead procurement packages for the equipment, valves, and instruments. In addition, a comprehensive schedule and execution plan which remedied the challenge of a very large amount of scope and limited time to complete. The advanced planning and collaboration resulted in a safe and successful 24/7 execution in 12 hour shifts for 14 weeks and turning over the manufacturing facility on time and with no disruptions to Biogen’s production timeline. 

Awards

  • ENR Southeast Safety Awards (2017)
    ENR Southeast
  • ENR Southeast Best Projects (2017)
    ENR Southeast

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