Late-Stage Biological Product Development Laboratory Renovation: Transforming Aging Infrastructure into a State-of-the-Art R&D Facility
Wunderlich-Malec provided engineering services to convert and existing 20+ year old 2-story lab facility into a renovated, state of the art Research and Developmental Lab Facility. The new R&D facility was designed to be equipped with latest technology trends pertaining to the biological fermentation processes currently being used in the industry.
Background & Project Requirements
A leading pharmaceutical company needed a new R&D Lab to focus on both small cell and large cell biological and chemical processes, including Fermentation, Filtration, Separation, and Concentration. The space must include production support services, including Environmental Controlled Storage Units, dedicated exhaust, specialty gases and waters, Pilot Plant Assembly area, Clean-inPlace, Sterilization-in-Place, Decontamination process and potential BSL-3 dedicated suite.
The building needed the capability to run on emergency power and UPS controls systems to ensure the experiments were not interrupted.
Wunderlich-Malec’s Solutions
Because a Pilot Plant with a higher room height was needed than the existing building could provide, it became necessary to explore the possibility of a new building. However, budget limitations eliminated the new building option. The Wunderlich-Malec design team developed a creative Hybrid solution, which involved a small addition (constructed at a higher ceiling level) while keeping the overall height of the existing building.
Construction services were implemented, while supporting an active lab facility, which involved critical (time and environment sensitive) experiments and process being run 24×7. The building continued to run on emergency power and UPS controls systems and experiments were not interrupted.
SERVICES Provided:
- Architectural Structural
- Civil
- Process Engineering
- Mechanical Engineering
- Electrical Engineering
- Project Management
SYSTEMS Included:
- Fire Alarm / Security / Paging
- Power Distribution (Normal + EP)
- Lighting • HVAC (w/ Dedicated Exhaust)
- Plumbing (w De-Con)
- Building Controls
- Process Integration
Customer Benefits
Wunderlich-Malec has proven Laboratory design experience implemented delivered a successful project on schedule and at a savings of $3.8 million below the client’s budget:
Solution: Innovative project design to meet customers functional requirements.
ROI: Savings of $3.8 million capital costs
Solution: Construction plan and Implementation that allowed continuous lab operations
ROI: No lost lab production experimental time or rework.
Solution: Multiuse Laboratory Facility
ROI: Provides customer flexibility in product experiments to meet their market demands
Solution: Used process tools to implement new process enhancements.
ROI: Reduced effort to implement process improvements and upgrades