OSD R&D/Pilot Plant Expansion Design + CM

Covidien / Mallinckrodt, Inc. Location: Webster Groves, Missouri Square Footage: 17,700 Construction Cost: $27,000,000

Project Description:

CRB provided turn-key design, procurement and construction management services for this major pilot plant addition to an existing Oral Solid Dose R&D building. The new pilot plant added significant capacity to the client's product development capabilities by permitting them to work simultaneously on up to five different drug products.

The pilot plant provides a breadth of processing capability housed in five functionally independent suites:

  • Granulation area equipped with a high shear granulator and fluid bed dryer with CIP capability.
  • Multi-purpose room which includes a large down flow booth and space for the new capsule filling equipment.
  • Tablet compression room with a small production scale tablet press (also CIP).
  • Blending room with multiple, interchangeable V-blender shells.
  • Weigh/dispense room with down flow booth and isolator.
Each processing room is served by an airlock system with separate material and personnel pathways and a "misting shower" incorporated into the personnel exit. The process facility is designed to handle potent compounds through the use of split butterfly transfer valves, isolators, and other engineered containment systems.

The processing area is supported by a Wash Room with COP Sink; a Clean Equipment Storage Area and a DEA Vault. The addition was constructed as a fully functional independent structure with new cooling tower, chiller, steam generator, HVAC system and USP water supply. It was tied into the existing building management, security and relocated emergency generator systems to permit the new pilot plant to seamlessly integrate into the existing research laboratory and product development activities.


2009 — DBIA: National Design/Build Award of Merit Winner
Category: Industrial Process — Under $25 Million

2009 — McGraw Hill Midwest Construction: National Best of 2009 Award of Merit Winner
Category: Industrial

2009 — DBIA: "2009 Mid America Region Design/Build Award Competition" Award of Merit winner
Category: Industrial Process — Under $25 Million

2008 - St. Louis Council of Construction Consumers: Best Practices Award Winner
Category: Project Start-up
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