When Eurogentec, a leading CDMO and provider of custom biopharmaceutical solutions, sought to upgrade their outdated process development lab at the onset of the Covid-19 pandemic in 2020, they turned to VILS. What began as a facility redesign quickly evolved into a deeper collaboration rooted in honest dialogue, critical problem-solving, and shared expertise. 

Confronting the Problem Head-On 

Eurogentec’s existing facility faced significant challenges. The lab, which played a pivotal role in scaling up client processes for GMP (Good Manufacturing Practices) readiness, was no longer suitable for operations. Although Eurogentec had been hoping the existing facility could be updated, our analysis showed that the only viable path forward was to demolish the facility and start from scratch. 

Designing for Today and Tomorrow 

We approached the project with our hallmark process-oriented mindset. Our team worked closely with Eurogentec to understand their needs, asking probing questions about workflows, equipment, and future scalability. Instead of replicating the old layout, we proposed a fresh design optimized for safety, efficiency, and flexibility. 

Our methodology started with asking what functions were needed, free from the constraints of the existing structure. We focused on capacity, process flows, and scalability to create a layout that worked for Eurogentec's present and future operations. 

Starting with a blank slate, we carefully analyzed process flows to identify potential bottlenecks and inefficiencies. Every square meter of the facility served a purpose, balancing capacity and functionality. 

For example, we meticulously planned the placement of equipment such as bioreactors and laminar airflow systems. By calculating the time each process step required, we configured the space to prevent underutilization and bottlenecks. This level of detailed planning guaranteed smooth operations without idle spaces or unnecessary downtime. 

This analytical approach extended to other aspects of the facility as well, such as ensuring efficient people and material flows. By rethinking the placement of clean utility points and combining certain functions, we created a layout that was not only GMP-compliant but also intuitive for Eurogentec’s team to operate. The result was optimized and aligned with Eurogentec’s operational needs. 

Key improvements included:

• Streamlined Workflow: Separation of upstream and downstream processing to eliminate cross-contamination risks.
• Future-Ready Design: Space allocation for potential expansions and upgrades, ensuring the lab could grow with Eurogentec’s needs.
• GMP Alignment: Tailored recommendations on where to mimic GMP conditions and where not, balancing quality assurance with cost-effectiveness. 

Although the idea of completely rethinking the layout was daunting for Eurogentec, after multiple discussions and thorough walkthroughs of the proposed plans, they embraced the approach. They saw the logic behind the flows, the allocation of spaces, and how the new design allowed their team to focus on their work with minimal disruption. 

Business-oriented delivery

Besides being process-oriented, our approach also kept business needs in mind at all times. To illustrate, we defined which areas needed to be GMP-compliant and which did not. This prevented unnecessary costs due to overengineering. 

Our process-oriented approach also applied to the way we staged the rebuilding in logical, process-oriented phases, allowing Eurogentec to keep other operations up and running and to resume operations as quickly as possible. For instance, the upstream processing area was prioritized, enabling cell growth and production to restart ahead of downstream activities. This phased approach ensured minimal disruption to their workflow. 

A Lasting Impact 

Despite the disruptions caused by the COVID-19 pandemic, we delivered the project on time and within budget. Today, the revamped lab is a showcase of the capabilities of both Eurogentec and VILS. It serves as both a functional workspace and a demonstration site for potential clients of both companies. The success of this project reinforced our reputation as a partner who brings ideas to life through expertise, transparency, and an unwavering commitment to quality. We don’t tell clients what they want to hear; we tell them what they need to hear. Eurogentec trusted us to guide them, and together, we built something remarkable.

Pictures: By Eurogentec - https://www.eurogentec.com/en/, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=116066180