Pharmaceutical Archives

March 9, 2026/in Pharmaceutical Engineering, Architecture U.S., Northeast U.S. Markets - Pharmaceutical /by Hannah Lee

SSOE partnered with Cipla on a comprehensive facility renovation and expansion to deliver a new inhalant medication manufacturing and packaging capacity. The project replaced an existing, undersized filling line with two new manufacturing suites capable of running simultaneous production and a new high-capacity filling line.

Manufacturing and filling areas were designed as ISO 8 cleanrooms within a cGMP framework, with secondary packaging and warehouse spaces planned as Controlled Non-Classified (CNC) environments. To accommodate increased raw materials and finished goods, the warehouse were expanded, and a new branded public entrance was designed to elevate the customer and employee experience. The extensive interior site clearance of existing areas also provided an opportunity to optimize the personnel and material flows for the entire facility. Other improvements included new gowning rooms, restrooms, and an administrative expansion.

The project also featured complete utility modernization including new chiller and air handling systems and updated electrical service, fire protection, security, and IT infrastructure to support the expanded operation. A dedicated propellant tank farm was installed to support the renovation.

From project initiation, our team led user group meetings to establish a program of spaces, adjacencies, and the final design of the diverse project components. We worked with the Owner’s India-based equipment manufacturers to locate and size the manufacturing, filling, and packaging spaces.

SSOE provided architectural, process, mechanical, electrical, plumbing, structural, and civil engineering for the project.

February 20, 2024/in Healthcare, Pharmaceutical Program / Project Management, Architecture, Master Planning Southeast U.S. Markets - Pharmaceutical /by Hannah Lee

Discovery Life Sciences (DLS) hired SSOE for the laboratory programming and planning for a new building to be located at their Huntsville, Alabama discovery center. DLS was looking to consolidate multiple laboratories under one roof to increase efficiency and modernize their laboratory spaces.

SSOE’s planning expert collaborated with the client user groups to create a program and optimized program customized to fit their unique needs. Working alongside the eight different laboratory user groups, the SSOE team generated a program that included space for a planned 25 percent growth across each of DLS’s business units.

After right-sizing DLS’s program, SSOE’s planning team created adjacency diagrams and blocking diagrams to plan out where different business units needed to be located within the building. One area that necessitated special consideration was the bio-repository, which needed to be centrally located within the building due to the potential risk of damage from natural disasters.

SSOE generated a program that consisted of just over 90,000 SF, utilizing a modular planning concept to allow future flexibility and adaptability. Laboratory spaces include wet research labs, a cleanroom, a BSL-3 laboratory, and genomics spaces.

The project’s flexibility and adaptability were tested when the genomics program director changed just as our team was finalizing construction documents. We swiftly pivoted, transforming the genomics space from an open lab into three separate labs, complete with anterooms and pass-throughs to accommodate the product

The genomics sequencing rooms house 30 sequencers, each of which emits a significant amount of heat. To address this, our team meticulously planned the space, incorporating specialized cooling and exhaust systems. These systems are connected to emergency power, ensuring that there will be no interruption to services in the event of a power outage.

Additional spaces include a cell services and processing lab, infectious disease, proteomics lab, donor center, immunohistochemistry services lab, histology, pathology lab, specialized biorepository for tissue samples in freezers, paraffin and slide-based samples, and shipping and receiving logistics room.

SSOE worked with the DLS to select the laboratory equipment and coordinated with equipment suppliers to ensure the required infrastructure was integrated to support the selected equipment. This project led to subsequent initiatives with DLS that persist to this day.

January 18, 2024/in Pharmaceutical Program / Project Management, Architecture, Engineering, Data / Fire / Security (DFS), Interior Design Southeast U.S. Markets - Pharmaceutical /by Hannah Lee

HCW Biologics needed to grow its operation and turned to SSOE to scale up. The client is transitioning from research and development to clinical trials for oncological and age-related medicine. With our Design-Build partner BE&K, SSOE provided full-service programming and planning, architecture, and engineering for the renovation of a 40,000 SF existing office, and warehouse space to be repurposed as laboratories, cGMP production spaces, warehouse, and support spaces.

Through workshops and collaboration with the scientific staff, our team generated a flexible and adaptable research laboratory. We worked with the client to develop their new production facility and guided the client through the development of their manufacturing procedures and established a Quality Assurance / Quality Control process.

Because the pharmaceutical industry is repatriating the drug manufacturing process, SSOE understood the client’s need to fast-track this project. Our national lab planner worked with HCW Biologics to ensure we were not repeating their smaller-scale configuration. Instead, we listened to the client to know what did and did not work in their limited operation to provide a more successful spatial arrangement in the designs for the larger operation.

SSOE designed spaces for specialty research labs including bioreactor, process, and microbiology, in addition to tissue culture and research laboratories. The new 5,000 SF cGMP cleanroom environment includes ISO 7 production labs and an ISO 6 sterile filling suite.

Finally, the project also included the addition of a new 1,000 SF vivarium space that is supplemental to animal holding including procedure rooms, isolation, and support spaces to facilitate vivarium operations. SSOE provided programming, planning, architecture, interior design, fire alarm, fire protection, technology, and structural, mechanical, electrical, plumbing, and process engineering for the project. Construction will be completed in March 2024.

March 3, 2022/in Pharmaceutical Engineering, Site Evaluation Midwest U.S. Markets - Pharmaceutical /by Hannah Lee

SSOE assisted a leading global life sciences manufacturer with developing Conceptual Design (FEL I), engineering estimates, and a program schedule for a new Active Pharmaceutical Ingredients (API) facility located in the Midwest. Forecasted demand for existing products cannot be accommodated within the owner’s existing facilities. As a result, SSOE developed a building concept to accommodate the increased manufacturing space, increased QA/QC and Micro Lab space, Stability Chambers, Product Development spaces, and general meeting and assembly spaces. The study also included investigating possible placement of the new building on the existing campus or locating it on one of two neighboring properties.

SSOE’s pharmaceutical design team collaborated closely with the client to create building conceptual design and site layout options, budgets, and an overall project schedule. SSOE fully integrated its Construction Management team into the project from Day 1 to provide a high level of estimate and schedule accuracy.

Building Highlights

The building network, instrumentation, and process equipment are being designed to allow full digitization of the manufacturing process.
The building will be comprised of ISO 7 (Micro Lab), ISO 8, ISO 9, CNC, and mechanical spaces.
Purified water (PW) and deinonized water (DI) generation systems will support manufacturing and laboratory spaces respectively.
Compressed gasses will be centrally located, and fully piped and instrumented delivery systems will serve both the production and lab spaces to completely eliminate the need for gas cylinders to be moved around inside the building.
Currently in Capex Funding Phase, detailed design is scheduled to begin in fall of 2021.
The estimated production start date is the 4th quarter of 2023.

March 3, 2022/in Pharmaceutical Engineering, Architecture Mexico Markets - Pharmaceutical /by Hannah Lee

To support a longtime client’s expansion into Latin America, SSOE was selected to design a new oral solid dose manufacturing facility in Mexico City following their acquisition of several product lines from a global healthcare company. The project involved a three-story, 50,000 SF building on a congested, active campus in the heart of the city.

The project presented unique challenges. The site’s location required construction to be carefully coordinated to avoid disrupting operations and city traffic. Building materials were sized for narrow streets and delivered overnight to minimize interference with local logistics and plant activities. SSOE’s team also needed to create space for the new facility, which involved relocating employee and truck parking, expanding the existing Quality Control Laboratory, converting a maintenance building into a GMP climate-controlled warehouse, and enlarging the parking garage—all while keeping operations running smoothly.

Technical complexity was another defining feature. SSOE increased purified water generation capacity and added a new system loop to meet the facility’s advanced requirements. The team designed a process waste treatment system to meter effluent and protect the city’s sewer service, and upgraded aging data, fire, and security systems. Recognizing the need for future growth, SSOE developed a master plan to allow production to double within the same footprint. Because raw material sampling and finished goods warehousing remained in the existing facility, a climate-controlled connector corridor was designed linking the new and existing buildings, serving both as a material flow path and a utility pipe bridge.

Throughout the project, SSOE leveraged Lean practices and an Integrated Project Delivery approach, supported by real-time design collaboration and a full-time engineering resource on-site. These strategies enabled the team to solve problems quickly, minimize disruption, and deliver a state-of-the-art facility that met the client’s immediate and future needs.

March 3, 2022/in Pharmaceutical Engineering, Architecture Southeast U.S. Markets - Pharmaceutical /by Hannah Lee

In an effort to double its current coated tablet production capacity, a leading nutraceutical manufacturer requested SSOE provide architectural, engineering, and construction management services to increase its production area by approximately 3,500 SF. SSOE led the design for simultaneous operation of two separate tablet coating processes, which included the installation of tablet coating equipment and utilities, an air handling unit with dust collector and blower, conveyor systems, a bulk unloading system, and relocation of the deionized water system. To allow for the capacity increase, SSOE designed expansions to the manufacturing area by utilizing available floor space for a new tablet coating room with auxiliary rooms for cleaning. Our structural team calculated and designed requirements to maintain structural integrity to support the new equipment.

SSOE’s structural, process / utilities, mechanical, and electrical disciplines provided a wide range of engineering services for process design and equipment layout. Our project management team developed the project budget and installation schedule, and oversaw contractor bid reviews and vendor drawing reviews. We also provided construction management services to reduce the cost of hiring a general contractor and matched hours to the project schedule requirements.

Our project team came through in the clutch by quickly adjusting to a “crash schedule” due to delayed project approval, and completed all installations by the established project completion date. In an effort to remain on schedule throughout the project duration, SSOE’s on-site construction management personnel worked weekends, holidays, and extended work week hours to make this project a success.

March 3, 2022/in Pharmaceutical Engineering, Architecture Southeast U.S. Services - Program / Project Management, Markets - Pharmaceutical /by Hannah Lee

SSOE has documented nearly $2 million in savings, including $1.6 million for the AMS upgrade project, $153,000 for the tray washer project, and $101,000 for the first set of conditioning rooms, corn syrup tanks, and kitchen platforms.

To keep up with consumer demand, a leading nutraceutical manufacturer needed to double its current gummy vitamin production capacity—increasing the current production area by approximately 8,200 SF. SSOE led the design for simultaneous production of multiple colors and flavors, which required modifications to the up front unit operations and an upgrade to the existing Additive Mixing System (AMS). Installation of bulk truck unloading transfer piping with heat tracing and two new 5,000 gallon corn syrup tanks was also included in the project scope. To allow for the capacity increase, SSOE designed expansions to the manufacturing area, seven new conditioning rooms, and a mezzanine to support a new heat exchanger without taking up valuable floor space. Our structural team designed safety enhancements in the kitchen areas by designing new access platforms. Additionally, SSOE designed a new COP room to accommodate new tray washing equipment to satisfy the flow of operations.

SSOE’s structural, process / utilities, mechanical, and electrical disciplines provided a wide range of engineering services for process design and equipment layout. Our project management team provided the project budget development and installation schedule, and oversaw contractor bid reviews and vendor drawing reviews. We also provided construction management services to reduce the cost of hiring general contractors and matched hours to suit the project schedule needs.

Due to delayed equipment arrival, the SSOE project team needed to quickly adjust to a “crash schedule” as the project moved toward completion. Understanding the urgency for speed to market, SSOE’s on-site construction management personnel worked weekends, holidays, and extended work week hours to meet the client’s desired completion date.

SSOE has since provided ongoing design and engineering services for this client, supporting the manufacturing of a variety of gummies including prenatal and food-based vitamins as well as fiber supplements.

June 26, 2018/in Pharmaceutical Engineering, Architecture International /by Hannah Lee

Kemin sought a research and development facility design that represents their entrepreneurial spirit and embraces the company’s energy and excitement for discovery. The laboratory and office spaces provide the basis for an orderly and innovative professional working environment.

The new R&D facility’s two-story lobby contains a large glass curtain wall and floor to ceiling external windows to allow natural lighting to flow into the facility. The entry and lobby are situated to establish a dominant façade, giving the building a formal presence on the project site. The front lobby contains a coffee bar with seating area, adding an extra collaboration environment for employees and customers. Reflecting the facility’s modern and concise style, a spiral, steel structured, glass stairway is the main vertical transport between the lab’s first and second floors.

The building’s floor plan was organized to facilitate efficient scientific analysis and interaction between labs and staff. This facility houses multiple lab types, including a general lab, specialized lab, pilot lab, laboratory support rooms, offices, and administrative areas. The pilot labs, mechanical rooms, and consumable items testing storage areas are located near the lab area, promoting internal experimental interaction and allowing for the central location of lab supplies. The general labs are open and modular, containing abundant natural light. Customers touring the facility will appreciate the flexibility of the general lab’s layout, allowing them to easily be reconfigured per the client’s needs.

May 31, 2018/in Pharmaceutical Master Planning, Engineering, Architecture U.S., Midwest U.S. /by david

SSOE was selected to create a master plan and design for Kemin to not only reflect the entrepreneurial spirit and corporate brand that is Kemin, but also to position the company appropriately for future projected growth. SSOE provided an overall assessment of the Kemin site to situate the new Research and Development (R&D) laboratory and future corporate headquarters in such a manner to promote oversight and engagement with the existing campus and manufacturing facilities, while also offering a formal gateway and introduction of Kemin innovation to the public.

The new R&D laboratory is designed for collaboration to promote intensive idea generation and product development. The two-story laboratory facility is organized with an emphasis on access to daylight, spatial efficiencies, and flexibility to expedite idea exchange and staff interaction. The main, general laboratory area is open and modular with specialty laboratories and related open office area located directly adjacent. Administrative offices, conference rooms, and informal meeting / break areas surround the primary laboratory function. Attached to the main laboratory are Class 1, Division 1 pilot laboratories which accommodate large-scale experiments and processes, a designated shipping and receiving area, chemical and sample storage areas, and mechanical / electrical services, including a generator.

The main entrance to the facility features an open, light-flled, two-story atrium. This common area presents visitors with a formal introduction to Kemin and will act as the central circulation hub to connect the future planned additions of a corporate administrative headquarters, 350-seat cafeteria and food service area, and an additional laboratory block.

SSOE has documented nearly $2 million in savings, including $1.6 million for the AMS upgrade project, $153,000 for the tray washer project, and $101,000 for the first set of conditioning rooms, corn syrup tanks, and kitchen platforms.

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Pharmaceutical

SSOE has documented nearly $2 million in savings, including $1.6 million for the AMS upgrade project, $153,000 for the tray washer project, and $101,000 for the first set of conditioning rooms, corn syrup tanks, and kitchen platforms.

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