Biologics manufacturing facility expansion
Key Statistics
Client
Janssen Sciences
PM Group Office
Ireland
Cost
$358m

Janssen Sciences UC (part of the J&J corporation) has completed c.19,000 sq.m. expansion to effectively double the size of its existing facility. The new ‘BioCork 2’ development at Ringaskiddy, Cork, incorporates an innovative ‘Fed Batch’ production process with four 5KL bioreactors. The development was winner of the ENR ‘Global Project of the Year (Healthcare)’ Award, 2020.  

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Andy Rayner
Andy Rayner

Pharmaceutical Sector Director

The project

The state of the art facility will produce new immunology and oncology treatments developed by Janssen. The addition to the new production building, the project also involved significant expansions to the warehouse, QC laboratories, finished goods freezers, office/admin and waste water treatment facilities. 

Construction of the BioCork 2 project commenced in 2017 and was completed in 2019. Production is expected to begin in early 2022, following the receipt of regulatory approvals

The 11,000 sqm production building was mainly designed as a single storey with the core process area on the ground floor. It is equipped with four 15,400L bioreactors for the manufacture of biologic drug substances. The facility is designed so that capacity can be further expanded with four additional 15k reactors.

Leading with sustainability

The new production building has been certified to LEED Silver standard (New Construction and Major Renovations v2009). The new labs and administration building is also certified to LEED Silver (Commercial Interiors v2009).

Key sustainable metrics

  • c.27% energy savings in building and process energy.
  • > 62% water savings.
  • 40% of electrical energy demand provided by on-site renewables.
  • > 99% of construction waste generated recycled.

Services

PM Group provided site evaluation, master-planning and permitting, architecture and engineering design, procurement, construction management support, commissioning/qualification/validation and LEED AP consulting services.


More about Janssen Sciences Ringaskiddy facility

In 2005 Janssen Sciences (previously named Centocor Biologics) established its Ringaskiddy operation on a c.40 hectare site. The award-winning greenfield BioCork 1 facility produces monoclonal antibody products. It incorporates perfusion cell culture and purification processes. PM Group and our partner designed and delivered the original €300m development.

Andy Rayner

Pharmaceutical Sector Director