Eli Lilly Biotech Pilot Plant, Indianapolis, USA

In October 2006 Eli Lilly completed the first phase of its biotech facility expansion in Indianapolis, which will be ready for use in the first quarter of 2007. The company is expanding its biotech capabilities to meet the demand of the growing number of biological drugs in its pipeline. The first phase of the $560m (€446m) project is a new bio products pilot manufacturing plant, which is expected to help the company design more efficient and productive manufacturing processes.

The new biotech manufacturing facility will produce small-scale quantities of experimental drugs for use in clinical trials. The facility has been constructed at a scale to allow it to operate up to one-half of the manufacturing capacity needed for full-scale commercialisation; the company hopes that this will assure a smoother transition from development scale to full-scale commercial manufacturing.

Lilly initially announced plans for the new biotechnology expansion in 2002. In 2004, those plans were expanded to nearly twice their original size to better meet the company's pipeline of biotech drugs.

BIO PRODUCTS R&D LABORATORY

Eli Lilly is also to open a bio products research and development lab; this will be opened during the first quarter of 2007 and will become their R&D nerve centre. At this new 475,000ft² facility, research will be conducted into molecular and cell biology, analytical science, pharmaceuticals and engineering and it will employ over 700 scientists and engineers.

RATIONALE

The construction of the new biotech manufacturing facility is partly to support Applied Molecular Evolution, a San Diego-based protein optimisation research company that Lilly took over in 2004. The takeover and the new manufacturing capacity will account for an estimated $1bn as part of Lilly's plan to bolster its biotech manufacturing and research capacity. At the current time about 30% (eight drugs) of Eli Lilly's drug portfolio are biotech-based and have sales amounting to around $3.6bn of the 2005 revenue of $14.6bn.

Eli Lilly would like to be in a position to play a larger role in the biotech pharmaceutical market in the future. Steven Paul, Lilly's executive vice president of science and technology, said: "Inside these new buildings, the latest in highly sophisticated technologies and equipment for conducting biotech research and development have been incorporated. Taken together – the facilities, the technologies, and an interdisciplinary approach – we've created a new model for Lilly that gives the company a competitive advantage in bringing breakthrough medicines to patients in a more efficient, productive, and dependable manner."

NEW BUILDINGS

Shiel Sexton is the project and construction manager for the biotech expansion project. Gaylor were responsible for the electrical design and engineering, ERMCO were awarded a contract for the installation of instrumentation and RTM Consultants were able to help with fire and building code regulations (Ryan Fire Protection Inc were the fire equipment supplier). Pharmadule Emtunga AB was the modular biotech facility designer and supplier.

The project was designated as K360, K361 and K362 after the name of each of the buildings. The K362 biotech development laboratory building (research support facility) is comprised of multiple developmental laboratories focusing on fermentation, purification and analytical development activities.

Adjoining office areas provide administrative space and other functional areas include small and large meeting rooms, rest areas, locker rooms and shop areas. The total floor space is 465,000ft² in a U-shaped configuration consisting of five storeys, of which one is a basement level.

The project has taken three years to complete at a cost of $150m. The K361 administrative support facility houses staff members for both K360 and K362. The building has a total floor space of 100,000ft² and cost an estimated $20m to construct.

The Lilly K360 biotech pilot manufacturing plant provides small scale (pilot) manufacturing for products to be used in clinical trials. The processes involved are more sophisticated compared to the manufacturing required for traditional small molecule drugs. The building has a total floor space of 211,000ft² and cost approximately $311m to construct.

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