Centocor BioCork, which was designed by PM Group and CRB Consulting Engineers, was named Sustainability Category Winner in the ISPE (International Society of Pharmaceutical Engineers) 'Facility of the Year' Awards 2009.
In 2001, Centocor started looking at options to provide additional manufacturing capacity for two promising new drugs in their pipeline. However, its existing manufacturing sites were built-out, so it was necessary to consider a greenfield site. In June 2004, after three years of study, Centocor approved funding to establish a new site in Ringaskiddy, County Cork, Ireland.
The overall mission of this project - dubbed BioCork - was to have 180kg-per-year biologic API capacity approved for market by June of 2010.
The BioCork project team worked closely with local residents to mitigate the impact of this large, complex project on the community. The project provided traffic mitigation alternatives, utilized advanced membrane waste water treatment, captured rainwater for recycling, and installed a biomass (woodchip) boiler for base steam load. This project also involved extensive landscaping that included planting 70,000 trees to mitigate visual impact and air quality. BioCork is 40% more energy-efficient than internal benchmark biotech facilities and there was a 90% reduction in the carbon footprint versus fossil fuel. In addition, through careful preparation, communication and implementation of safety planning, BioCork is one of the safest large projects ever built in Ireland.
Through use of integrated budgeting and scheduling, coupled with full user participation, this complex project was completed ahead of schedule, under budget and exceeded capability requirements in all areas, especially in the sustainability category.
PM Group and CRB Consulting Engineers designed and delivered this project (with Sisk acting as construction managers.)
- Site Evaluation, Masterplanning and Permitting
- Architecture and Engineering Design
- Construction Management Support
- Commissioning and Qualification
Facility Of The Year website