Bulk Biological Manufacturing Facility

Centocor, Inc. Location: Cork, Ireland Square Footage: 263,000 Construction Cost: $325,000,000

Project Description:

CRB, with a local partner, was responsible for the site selection, engineering design, procurement and validation (VMP & DQ) of this state-of-the-art Greenfield biological manufacturing facility located in Ireland. The plant will produce bulk biological products using 3 x 1,000L perfusion bioreactors.


The facility consists of four separate buildings totaling 24,400 m2, connected by a central spine/walkway. The four buildings include:

  • Production Building
  • Central Utilities Plan
  • Warehouse
  • Administration and Laboratory Building

Supporting site infrastructure, also part of the design, includes a utility yard, wastewater treatment plant, roads, vehicle parking and significant landscaping.


Major equipment / systems defined for the facility includes pre-culture / cell culture, product recovery, purification, media preparation/hold, buffer preparation / hold, cleaning and sterilization systems, GMP utilities, and waste inactivation / neutralization.

The front-end study of this project was executed by the CRB / PM project team located in CRB's Philadelphia office, with planning and environmental impact statement being completed simultaneously in PM's Cork, Ireland office. Detailed design was completed by the CRB / PM project team located in PM's Cork office. The project utilized intelligent P&IDs and was designed fully in 3D.

Basis of design for the project started in 4Q 2004, and detailed design was completed 2Q 2006. Commissioning started in mid-2006, with construction complete and all systems planned for turnover in 2007.

Awards: 2009 ISPE Facility of the Year Award, Sustainability

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