Reference Projects
Selected recent modular and turnkey delivery projects
Unique vaccine plant
On a difficult site
When a pharma company wanted to expand one of its European vaccine manufacturing and aseptic filling plants, it turned to KeyPlants for the complex, hybrid project, which used both modular and conventional construction techniques.
Modular pharmaceutical packaging facility
Designed and delivered on 12-month timeline
When a leading global pharmaceuticals company wanted to expand production of one of its products in Austria, it once again turned to KeyPlants to build the necessary cleanroom for its packaging line.
ISO Grade 7 cleanroom solution optimizes production flow
When a Swedish company that has a patented surface coating for devices designed to be implanted in the human body needed a new production facility in a leased building, they called on KeyPlants to provide a turnkey solution.
Institut Pasteur de Dakar (IPD): First-Of-Its-Kind Vaccine Manufacturing Facility to Africa
Driving self-sustaining COVID-19 vaccine solutions in Africa
Our team at KeyPlants, together with a group of international companies, funders, and governments, have designed and built a first-of-its-kind vaccine manufacturing filling facility in Senegal, Africa. Project MADIBA leverages our unmatched expertise and vast experience in modular solutions and off-site manufacturing to develop this transformative facility in under a year. Owned and managed by Institut Pasteur de Dakar (IPD), the facility will revolutionize access to vaccines in Africa…
Modular biomanufacturing and aseptic filling facility, Latin America
Scope: Delivery of an outdoor modular facility of 6.300 sq. m. including all process equipment. Facility based on KeyPlants design platform Modular Bio Solutions (MBSTM).
Major drivers: Predictability, Speed, Quality
Objective: Turnkey delivery to greenfield site.
Multi-product biomanufacturing facility, Sweden
Scope: Process simulation, design and project delivery including C&Q. Buffer hold, CIP, clean utility, change of process streams and upgrade of process automation system.
Major drivers: Predictability, Quality, Schedule, Experience
Objective: Near doubled the site production capacity.
Saudi Bio, Saudi Arabia
Modular aseptic formulation and filling facility
Scope: Delivery of an indoor modular facility based on KeyPlants design platform Modular Aseptic Solutions (MASTM). Filling of vials, cartridges and pre-filled syringes, including lyophilization.
Major drivers: Predictability, Speed, Quality, Flexibility
Objective: Turnkey delivery of a qualified facility in 16 months.
Ferring, Germany and Indonesia
Modular movable filling facility
Scope: Turnkey delivery of an indoor modular facility to Germany for commissioning and training of personnel. Further delivery to final site in Indonesia.
Major drivers: Rapid deployment, overcome Tech Transfer challenges and accelerated approval
Objective: Turnkey delivery of a movable facility.
Galderma, Sweden
Aseptic filling facility, BSL-3
Scope: Pilot scale aseptic filling facility in an existing building. Vial filling line in isolator.
Major drivers: GMP compliance
Objective: Facility for new product launches.
Big Pharma, Sweden
Compounding and dispensing suite
Scope: Installation of new clear room area including integration with existing systems (HVAC, Electrical, Sprinkler, Automation etc.).
Major drivers: GMP compliance, minimal interference
Objective: Design and execute with high predictability to a fixed budget and timeline.
Merck & Co, USA, Netherlands
Modular Ammonia Plant
Scope: Design, off-site construction, on-site installation and integration.
Major drivers: Safety, speed and predictability
Objective: Turnkey delivery of the ammonia plant on a congested site within 6 months.
Teruisi Pharmaceutical Inc., China
Greenfield Mab Manufacturing Facility
Scope: Conceptual design for greenfield facility together with Hyde Engineering. Fabrication and delivery of purification and bulk filling modular skids.
Major drivers: GMP compliance, predictability
Objective: Turnkey delivery of GMP-compliant skids including site integration to schedule and budget.
Merck & Co, USA
Weighing and Dispensing Facility in Switzerland
Scope: Basic design, fabrication, integration of process equipment, assembly.
Major drivers: Speed
Objective: Turnkey delivery of the facility through off-site construction within 6 months
Stragen Pharma, Switzerland
High Containment OSD Facility, Greenfield
Scope: Design, off-site fabrication, on-site installation and qualification of an OSD manufacturing facility.
Major drivers: GMP assurance, predictability, speed
Objective: Turnkey delivery of a qualified OSD facility within 15 months
Teva Sicor Biotech UAB, Lithuania
Skid Delivery Project, Expansion project
Scope: Design, fabrication and qualification of modular process skids
Major drivers: Quality, schedule, cost
Objective: Turnkey delivery and qualification of modular protein solution skids within 6 months
Biotechpharma UAB
Skid/Equipment Delivery Project
Scope: Turnkey delivery and qualification of buffer and protein solution skids.
Major drivers: Quality, schedule, cost
Objective: Design, manufacturing, start-up, IQ/OQ and handover on site within 6 months
Teva Sicor Biotech UAB, Lithuania
Skid Delivery Project, re-order
Scope: Turnkey delivery and qualification of modular process skids
Major drivers: Cost, schedule, quality
Objective: Design, fabrication, start-up and IQ/OQ and handover on site within 10 months
Octapharma, Sweden
Capacity increase project with skids and off-site construction
Scope: Expansion of plasma fractionation facility. Installation of tanks and clean utility systems including piping.
Major drivers: Short and predictable installation during production stop
Objective: Increase capacity with limited time for installation.
