Expanding biopharmaceutical manufacturing capacity at scale

Project overview

 

A leading contract manufacturer serving the pharmaceutical and biotechnology industries required new processing infrastructure as part of a major expansion project in Portsmouth, New Hampshire. The project involved the design and fabrication of two large-scale process skids supporting pre-viral and post-viral manufacturing operations. Exentec provided the engineering, design and fabrication expertise needed to deliver a solution capable of supporting high-capacity biopharmaceutical production

 

The challenge

 

The project presented significant engineering and coordination challenges due to the scale of the process systems involved. The skids incorporated large process vessels, extensive filtration systems and substantial piping networks within a constrained manufacturing footprint. The client required a solution that would maximise processing capability while overcoming physical space constraints and avoiding clashes between large-diameter process lines. Maintaining constructability and operational efficiency throughout the design process was critical to project success.

 

Exentec's solution

 

Exentec designed and fabricated two fully integrated processing skids to support both pre-viral and post-viral operations. The scope included process engineering, piping design, instrumentation, structural support systems, fabrication documentation and factory testing. The solution incorporated multiple high-capacity process vessels, integrated filtration systems, structural mezzanines and associated process infrastructure. This provided a complete platform ready for installation and commissioning within the client's manufacturing facility.

 

The results

 

Exentec successfully delivered complex, large-scale manufacturing infrastructure that expanded the client's biopharmaceutical production capability. Through detailed engineering development and coordinated design execution, the project overcame significant space and integration challenges whilst providing a scalable platform for future growth. The completed systems support efficient commercial manufacturing operations and demonstrate Exentec's ability to deliver critical process infrastructure for some of the world's most demanding biopharmaceutical environments