Hybrid biopharma facility sets new standards in single-use and stainless-steel integration.

This project exemplifies the future of biopharmaceutical production: a hybrid facility that seamlessly integrates single-use (SU) systems within a stainless-steel infrastructure. The plant’s “dancefloor” layout concept allows for intelligent clustering of modular units, enabling efficient upstream, midstream, and downstream processing within a single module. ZETA’s scope included the detailed design of clean rooms, complex media supply infrastructure, and the fabrication and installation of a stainless-steel backbone. The result is a highly adaptable, multiproduct system that sets new standards in hybrid facility design.

The project faced significant spatial and technical constraints. The layout had to accommodate a wide range of equipment and furniture while ensuring operational efficiency, safety, and compliance with GMP standards. Clean room classification, pressure cascading, ATEX zoning, and ergonomic considerations were all critical.

ZETA addressed these challenges through meticulous 3D modeling, enabling precise visualization and space optimization. The team also developed custom platforms with integrated tubing and innovative solutions like hermetically sealed floor ducts and flexible filter holder systems. The dynamic nature of the project required continuous adaptation, with layout and piping plans evolving in parallel to meet tight deadlines and changing customer requirements.

From contract award to mechanical completion in just 14 months, the project was a model of ultra-fast-track execution. ZETA’s engineers demonstrated exceptional agility, responding to evolving project scopes and integrating frequent customer change requests. A collaborative project culture was key: ZETA built a strong intercompany team, maintained close communication with the client, and coordinated effectively with equipment suppliers. Customized procurement catalogs accelerated sourcing, while ZETA’s on-site team ensured seamless integration of all stakeholder needs. The result was a facility delivered on time, within budget, and to the highest quality standards – an achievement that underscores ZETA’s leadership in hybrid biopharmaceutical plant engineering.