In 2020, when the world came to a standstill during the COVID-19 pandemic, we were just getting started on one of our most ambitious projects yet: Designing and managing the construction (ECPM) of an advanced, 8,000-square-meter viral vector and biologics production facility for Exothera, a subsidiary of Univercells.
Exothera is a CDMO specialized in developing and manufacturing viral vectors and vaccines for gene therapy and other advanced therapies. It supports companies in bringing innovative therapies to market efficiently by providing end-to-end services, including process development, scale-up, and GMP manufacturing.
The timeline for the project was ambitious: Just 18 months to move from concept design to delivery of a cGMP-compliant campus in Jumet, Belgium. With existing commitments to its clients, any delay in completing the facility could result in substantial revenue loss for Exothera – and potentially delay the delivery of treatments to patients.
Our process-based approach to designing facilities and our focus on eliminating redundancy are tailor-made for delivering complex facilities on challenging timelines. Both enabled us to successfully execute what was at the time our largest and most complex EPCM project.
A partnership that began with the process
Exothera came to us with a clear mission: to tackle bottlenecks in the cell and gene therapy market by creating a state-of-the-art facility that could support vaccine production, R&D, and quality control labs. The scale and speed made this project exceptional.
At VILS, we never retrofit generic blueprints; we design facilities from the ground up, starting with the client’s process and business objectives. This means every project starts with a deep understanding of the client’s needs and concludes with a facility that is more than just functional. It is purpose-built to help the client’s business thrive.
For example, Exothera, as CDMO, required a lean facility design optimized for current process efficiency while remaining adaptable to accommodate future client products. And, as with every facility we design, we also prioritized the human element – designing workflows that make daily operations intuitive and efficient, never unnecessarily complex.
These and other considerations had to be translated into the layout and facility design to ensure that the facility's capabilities precisely aligned with Exothera’s business objectives. In Exothera’s case, we were delivering more than a facility. We were delivering a competitive advantage.
Integration, continuity, and a focus on the essential
After aligning our work with Exothera’s process and business objectives, the way we managed the project would prove to be a key success factor. From day one, we worked as an integrated team, collaborating closely with Exothera’s technical staff and contractors. By involving contractors early and skipping lengthy tendering processes, we shaved months off the timeline.
In addition, a core team of our process architects and engineers stayed with the project from concept to commissioning, instead of handing off responsibilities at different stages. This continuity not only prevented the delays that come when bringing new people up to speed, it ensured that every detail was aligned with the original vision.
Like many large-scale projects, this one wasn’t without its surprises. For instance, the existing building shell required significant modifications, including reinforcing floors, installing micro-piles, and cutting trenches for utilities. New stakeholders joined midway through, bringing fresh ideas that, while valuable, could have derailed the timeline. However, by maintaining open communication, staying agile, and focusing on the essential, we successfully navigated these shifts without compromising the schedule.
Results that speak for themselves
Eighteen months after we started, the facility was up and running – a GMP-compliant plant licensed by the European Medicines Agency (EMA). Despite the constraints of the pandemic, we delivered a facility that exceeded expectations and positioned Exothera to accelerate the delivery of cell and gene therapies to market.
For us at VILS, this project was a continuation of our achievements in the life science industry, from building the world’s first GMP-approved mRNA production facility to this state-of-the-art viral vector campus. Whether it’s translating complex scientific processes into operational excellence or delivering facilities on time and on budget, we’re here to help our clients turn their visions into reality
