A leading pharmaceutical client required a “gut-and-rebuild” solution for an existing production facility that produced vaccine for global applications. Morrison Hershfield was chosen as Prime Consultant to program and lead this fast-track, time-sensitive assignment, and provide project management/design services.

Key project drivers included:

• Isolation of production areas to meet national standards for Containment Level 3
• Modifications to meet current Good Manufacturing Practices (cGMP)
• Accommodation of new fermentation and downstream processing equipment
• New gowning rooms for PPE and wet shower egress
• New liquid effluent (kill tanks) and waste decontamination (autoclaves)

Design solutions included:

• Robust finishes
• New failsafe wall/ceiling assemblies to contain air borne pathogens
• Air pressure resistant (APR) doors
• New mechanical/electrical infrastructure and BMS
• Building envelope upgrades and access control systems

Impact on operations was limited to a six month timeline, to meet production commitments and allow time for re-qualification of production environments. The design solutions were managed to ensure compliance with user requirements, CL3 requirements and efficiencies were achieved to meet budget targets.

Morrison Hershfield provided full-time site presence to track progress, troubleshoot coordination issues, and assist in the commissioning of the facility to ensure compliance with Statement of Requirements.