Anatomy of a Pharmaceutical Plant: Second in a 3-Part Series Examining the Financial Impact of New Plant Construction

---

Reported by Annette Kreuger, Industrialinfo.com (Industrial Information Resources, Incorporated; Houston, Texas). As construction begins on a new pharmaceutical or biotech plant, the financial impact resonates across an incredible number of companies. For illustrative purposes, this article will give an overview of Merck’s $300 million vaccine manufacturing plant that is now under construction at Treyburn Corporate Park in Durham, North Carolina.

Merck assembled a formidable team of architects, engineers, and contractors, including Turner Construction Company, Fluor Corporation, Jacobs Engineering Group, Flad & Associates, Affiliated Engineers Incorporated and the John R. McAdams Company. All are working on various design and construction phases of the 272,000 square-foot manufacturing campus. Of course, a number of subcontracting firms (carpenters, plumbers, pipefitters, painters) are also required for construction, benefiting the local and state economy. Site work for the plant began in late 2004, with the entire construction process expected to employ approximately 500 throughout the life of the project, which is expected to be complete in 2008.

Construction of the vaccine plant requires an incredible amount of equipment and other products. In addition to a 166,000 square- foot manufacturing facility, the project will include an 80,000 square-foot warehouse (both cGMP -certified good manufacturing practice and non-cGMP) and a nearly 9,000 square-foot energy center. In the warehouse alone, a brief list of equipment required includes freezers, scales, mechanical and electrical instrumentation, computers, site communication and data collection equipment.

The shipping and receiving areas, pipe shop and mechanical control center must also be equipped. The energy center will house water and glycol chillers, air compressors, circulation pumps, condensation tanks, air compressors, dryers and mechanical control room areas.

The actual vaccine manufacturing plant calls for a staggering amount of equipment from a variety of suppliers. Bioreactors, process controls and automation, ultrafiltration, process vessels and cleanroom equipment are just some of the key items needed. Piping is needed for delivering chilled water, deionized (DI) water, water for injection (WFI) and compressed air for cleaning, rinsing and drying activities. Other essential equipment includes filtration, washing and fill and finish equipment.

While high-tech manufacturing equipment is to be expected, it is easy to overlook the somewhat more mundane products and services required for a new plant. Essential items needed include floor and wall coverings, cabinetry, window coverings, office furnishings, light fixtures, benches, signs and restroom fixtures. The list continues with parking lot paving and striping, external signage, landscaping and sprinkler systems.

The next and final article of this series will look at the financial impact that follows the construction of a pharmaceutical or biotech plant. Who gains what when the plant begins operations?

Click on the image at right for information on our North Carolina Industrial Plant Demographics Wall Map.

View Plant Profile: 1057397
View Project Report: 15001554

Industrial Information Resources (IIR) is a Marketing Information Service company that has been doing business for over 22 years. IIR is respected as a leader in providing comprehensive market intelligence pertaining to the industrial processing, heavy manufacturing, and energy-related industries throughout the world.