The Biocon Biologics Manufacturing Plant (B3), the latest addition to the biopharmaceutical company’s 100-acre Biocon Park in Bengaluru, India, is no smaller accomplishment.
Stretching 340,000 square ft and costing $120 million (USD), it is now the major monoclonal antibodies (mAbs) facility in India in sizing and expense.
Regardless of this sizing and complexity, Jacobs fast-tracked the job and assisted style and design deliverables to realize B3’s mechanical completion in just 24 months of thorough structure.
Jacobs also integrated sustainability in its style and design, minimizing energy consumption and waste. Most importantly, with the greater ability and operational effectiveness the facility presents, Biocon Biologics can present its products and solutions at reduced prices.
For all these feats, the B3 facility has received an Honorable Point out for the International Culture for Pharmaceutical Engineering’s (ISPE) 2021 Facility of the 12 months (FOYA) awards. In its posting detailing the project, ISPE regarded B3 for its sustainability, protection, revolutionary technique, and alignment with Biocon Biologics mission.
Examining all the bins
Biocon Biologics came to Jacobs with an formidable goal and a lengthy checklist. The intention of the B3 venture was to develop a condition-of-the-art facility that boosts production potential for recent solutions and adapts to long term commercial products. A restricted concentrate on offer chain would guarantee that B3 expanded item ability though driving down fees. The facility should really also be adaptable – it ought to be in a position to accommodate unique industrial products and solutions in the long term.
Even so, operational effectiveness would not arrive at the cost of sustainability – the Biocon Biologics group nonetheless needed the design and style to take into account energy conservation. Biocon Biologics also needed that the facility serve as an extension of its campus and combine utilities from a centralized utility developing.
At last, all these specs experienced to be achieved securely, all on-plan and within budget.
Higher than and past
Shoulder to shoulder with Biocon Biologics, the Jacobs structure crew acquired to work. Instead than implementing one wholesale design and style tactic, the layout group very carefully analyzed every single component of facility design, devices collection, and qualification to select the most appropriate technique for each and every scenario.
The outcome: a multiproduct facility that manufactures, purifies, formulates and bulk fills cell-culture therapeutic solutions using huge-scale procedures on a marketing campaign basis. A few floors household anything from administrative and operational office environment place to upstream and downstream processing and an in-system high quality manage tests lab. The facility takes advantage of integrated preparing, in which all areas are related still divided functionally to accomplish functions independently devoid of interference or cross-contamination.
In addition to operational performance, Jacobs crafted sustainability into its style and design. All office and meeting rooms facial area East and Northeast, minimizing heat from the sunshine whilst continue to enabling for normal mild – conserving lighting energy and cutting down HVAC cooling load. The plant also utilizes a rainwater harvesting tank and an inner zero-discharge effluent h2o therapy plant to reuse water on site. Furthermore, condensate from steam is saved and recycled by means of the boilers to further more decrease use.
The Jacobs team optimized gear distribution and procedure to lower fees, which could enable Biocon Biologics in switch minimize the price of medicines to consumers. Also, the facility is flexible – this adaptability enables corporations to pivot production in reaction to events like drug shortages and health and fitness crises. These functions align the facility with Biocon Biologics’ mission to manufacture affordable, lifesaving and everyday living-impacting solutions all over the world.
Biocon Biologics is the very first biopharmaceutical firm from India to get an ISPE FOYA Honorable Point out. In addition to Biocon Biologics, Jacobs has a lengthy heritage of serving consumers who have been acknowledged as Facility of the Yr award recipients. Considering the fact that the awards’ inception in 2006, more than 15 Jacobs shoppers have been recognized.