Genesis joined forces with Bayer Healthcare to tackle the intricacies of cGMP facility modernization within a historic and outdated 1940s structure. Through rigorous planning, application of state-of-the-art EPCM techniques, and a dedication to minimal disruption, this partnership successfully transformed an older building into a renovated and contemporary manufacturing facility.
Genesis’ approach to their Advanced Manufacturing Systems helped this market leader increase their operational efficiency. By integrating an Automated Ingredient Dispensing/Mixing System, we streamlined their process, resulting in faster manufacturing and consistent product quality. Within their Continuous Coating Operation, we facilitated a smoother coating process to increase productivity and ensure product quality.
After recognizing challenges posed by ongoing construction, we phased the construction, carefully planning the activities in isolated segments. This allowed regular manufacturing operations to continue without disruption. Through collaboration with Bayer’s Site Operations teams, we were able to gain alignment and move forward seamlessly. We also implemented a parallel qualification and construction strategy. This practical approach expedited the turnover process, ensuring that the facility could be occupied promptly once construction was completed.
In conclusion, the successful cGMP facility modernization of Bayer Healthcare’s historic building demonstrates Genesis AEC’s expertise in EPCM engineering. By integrating advanced manufacturing systems, ensuring minimal disruption to ongoing operations, and implementing a parallel qualification and construction strategy, we delivered a state-of-the-art facility that met Bayer’s strict cGMP requirements while enhancing their production capabilities. Our collaborative approach and commitment to innovation allowed us to overcome the unique challenges posed by modernizing an older structure, resulting in a project that exceeded expectations.