As the global pandemic intensified, NewAge Industries recognized the critical need for increased production of medical-grade tubing. The company invested in a state-of-the-art medical-grade tubing manufacturing facility under the U.S. government’s Operation Warp Speed initiative to address this urgent need. This new facility played a pivotal role in meeting the surging demand for essential medical supplies.
NewAge Industries partnered with Genesis AEC to renovate and upgrade their secondary manufacturing facility into this cutting-edge medical tubing facility. The facility was specifically designed for the production of single-use thermoplastic tubing products. This facility included a dedicated 18,000 sq ft area where Genesis installed seven ISO 7 cleanrooms. These cleanrooms have top-tier HEPA filtration systems to maintain optimal air cleanliness standards, allowing no more than 10,000 particles per cubic foot.
Apart from the specialized manufacturing area, the site also integrated warehousing and support spaces. These additional spaces were strategically designed to enhance NewAge’s operational workflows, leading to a significant increase in their overall efficiencies.
Challenges Faced in Constructing the Medical-Grade Tubing Manufacturing Facility
Launching such a pivotal project during a global pandemic was not without its challenges. With disruptions in the supply chain, unpredictable material lead times, and varying contractor availability, the scenario was less than ideal. Adding to the complexity, the facility chosen for the renovation was a warehouse from the late 1980s, requiring comprehensive electrical upgrades to meet modern standards.
However, despite these multifaceted challenges, Genesis’ team showcased their commitment and expertise by completing the entire design and construction process of the facility in an impressive span of 18 months.
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Glossary
- Operation Warp Speed: A U.S. government initiative aimed at facilitating and accelerating the development, manufacturing, and distribution of COVID-19 vaccines, therapeutics, and diagnostics.
- ISO 7 Cleanroom: A controlled environment with a specified level of particulate contamination, defined by the number of particles per cubic meter at a specified particle size. ISO 7 cleanrooms maintain air cleanliness to have no more than 352,000 particles sized 0.5μm or larger per cubic meter.
- HEPA Filtration: High-Efficiency Particulate Air (HEPA) filters trap harmful particles such as pollen, dust mites, and tobacco smoke.