Morphotek’s New Biologics Production Facility, United States of America

Morphotek, a subsidiary of Eisai Co, is constructing a new manufacturing plant for the production of biologics for early phase clinical trials. The new facility will be located in Welsh Road, Exton, Pennsylvania. It will be completed in 2011 with operations scheduled to begin in 2012. The $80m plant has been designed for LEED (Leadership in Energy and Environmental Design) certification by the US Green Building Council at the silver level or higher.

The company currently has 200 employees and will hire 30 to 50 people in 2012. Upon starting the production of its first drug, the company will construct a new manufacturing building in the area over the next three to five years.

Facility

The 60,000ft² facility will accommodate a biologics plant, a cGMP warehouse and loading dock area, and offices. The biologics plant will include ISO 5, 7 and 8 clean rooms for cell culture, purification and formulation. A fill finish suite has also been planned for the future. The facility will additionally house a cold storage area, quality control laboratories and mechanical and process equipment rooms. An interior equipment platform and an interstitial catwalk system will be installed within the facility.

A fully transparent glass corridor will provide a complete view of the clean rooms, manufacturing suites and the mechanical systems while in operation. The design will allow easy tour of the facility without dressing into clean-room gowns.

The facility has been designed to use 30% less water and 33% less energy than a conventional building of a similar kind. To minimise glare and heat gain, the building shell will be incorporated with exterior solar shading devices, roof overhangs and high performance reflective glass curtain walls. Light shelves will be installed to maximise the interior day light and minimise solar heat gain.

Additional design features will include prefabricated and insulated metal wall panels, Pennsylvania bluestone accent and a white membrane roof that allows the building to reflect and convert 90% of the solar power into short wave radiation. To further minimise the usage of energy, an open floor interior design plan will be implemented together with energy saving devices including daylight and occupancy sensors on the lighting. The facility will be furnished with Greenguard indoor air quality certified systems furniture to minimise emissions.

Construction

Construction of the facility has involved the demolition of three buildings. Recycled and renewable building materials, including the remains from the demolished buildings, are being used for the construction.

Other sustainable features of the design include on-site energy generation and an aggressive construction waste management plan that allows divert over 75% of construction waste from landfills.

Contractors

The contract for the project's construction management has been awarded to HSC Builders & Construction Managers. Precis Engineering has been appointed to provide mechanical, electrical, plumbing (MEP), process engineering and commissioning services for the project. The company used Autodesk Revit MEP software to develop the engineering design.

The software is a new Building Information Modelling (BIM) tool with advanced 3D coordination features. It offers project visualisation in real time at every phase of the design process, enabling the company to streamline its design and decision making process. A 3D animated video was also provided to demonstrate the look and functioning of the finished facility and its systems.

The contract for the project's architectural services was awarded to Exton based Arcus Design Group Architects. MacIntosh Engineering was chosen to provide structural engineering services while Re:Vision Architecture was appointed as the LEED consultant. Other contractors involved are Chester Valley Engineers for civil engineering and site survey, and CVE to assist in the LEED Certification.