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Boehringer Ingelheim Pharma GmbH & Co. KG – New solids launch facility

The pharmaceutical company Boehringer Ingelheim Pharma GmbH & Co. KG wanted to establish a new central launch and production facility with containment requirements (OEB4) within the Boehringer network in Ingelheim. The new facility should on the one hand be highly flexible and modular for the manufacturing of launch products and on the other hand implement “state of the art” containment technologies. To be very flexible for future needs, the complete design of the facility had to be adaptable for other manufacturing processes easily and room for expansion had to be given.

Pharmaplan started with the development of an extended feasibility study, where the given customer requirements were challenged and integrated into a facility design.

In that facility design energy and media supply function are placed in the basement, the ground floor is used for the manufacturing area and the first floor includes the central ventilation area. The facility design considered a “train-concept” to separate the production areas from the central support areas via personal and material EHS-locks. The building concept adapted on optimized room sizes based on equipment dimension and manufacturing operation. For easy implementation of future technologies without interrupting manufacturing process, the layout and the facade were designed to allow the implementation of technical process equipment easily.

Design Highlights

Besides the successful project execution in time and budget, an additional highlight of this large-scale project was the outstanding safety performance during the construction phase, driven by individual accountability and behavior.