Large-Scale Cell Culture Greenfield Concept

Novartis Pharmaceuticals Location: Basel, Switzerland Square Meters: 46,500 Construction Cost: $500,000,000

Project Description:

CRB provided process engineering services for the conceptual, basic and detailed design of a Major Expansion Cell-Culture Capacity Greenfield project for the manufacture of multiple biopharmaceutical products by large-scale cell-culture technology. The facility, to be located in Tuas Biomedical Park, Singapore, will support production of potential new biopharmaceutical therapies. The $500MM facility is comprised of Clinical and Commercial manufacturing operations connected via a central supply spine to shared process support areas and warehouse as well as required facilities for functions like Development, QA/QC labs, Canteen, Administration, and Utility Supply. 

The manufacturing area was designed to be divided into two independent and separated zones, one dedicated to the manufacture of clinical material and one dedicated to commercial production.

The biopharmaceutical complex consists of:

  • Clinical Manufacturing Building consisting of 4 stories totaling 10,800 m2
  • Commercial Manufacturing Building consisting of 4 stories totaling 8,200 m2
  • Shared Functions Building consisting of 3 stories totaling 6,300 m2
  • Warehouse consisting of 2 stories totaling 3,100 m2
  • Spine corridor, 4 stories with pipe rack totaling 3,000 m2
  • Administration Building with offices, QC and Development Laboratories, Reception Lobby, 5 stories totaling 11,200 m2
  • Staff Canteen & Cafeteria, totaling 1,100 m2
  • Plant utility Building consisting of 2 stories totaling 1,800 m2
  • Waste water Treatment Facility, totaling 1,050 m2
CRB was responsible for development of the process design, including mass balance, PFDs, operational descriptions, P&ID modules, P&IDs, process design data, detailed design specifications, and assistance in functional specification development for USP, DSP, Final Fill, Buffer Hold, Media/Buffer Prep and CIP "systems. CRB was also responsible for development of Long Delivery Process Equipment and Super Skid procurement strategy, specifications, bid documents, technical evaluation and procurement support for pre-purchased equipment packages.

CRB was teamed with Foster Wheeler for completion of Concept Design and Jacobs Engineering for completion of the Basic and Detailed Design. CRB's effort was executed by our team located in Basel, Switzerland with overall project delivery coordinated and executed simultaneously between teams located in Europe, UK and Singapore.
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