Lonza Biologics Expansion Singapore (LBXS1 and LBXS2)
Procurement Management and Process Engineering Design for Pharmaceutical Manufacturing Facility
Lonza Biologics is the world’s leading supplier of active chemical ingredients, intermediates, and biotechnology solutions for the pharmaceutical and agrochemical industries. Lonza is also the leading contract manufacturer of therapeutic monoclonal antibodies and recombinant proteins from mammalian cell cultures. To address its expanding markets, Lonza initially selected Parsons in 2000 as its program manager for an engineering, procurement, and construction management project that expanded Lonza’s East Coast facility in Portsmouth, NH. Because of our shared success on this state-of-the-art facility—the new production plant was completed in late 2003 and began product manufacturing in May 2004—we have worked in tandem with Lonza to improve its efficiency and effectiveness by providing operational support to its major expansions at other facilities, in addition to receiving more than $50 million in supplemental projects at its Portsmouth facility.
However, to continue strengthening its leading position as a global custom manufacturer of biopharmaceuticals, Lonza required increased large-scale contract manufacturing capacity. In 2006, Lonza selected Parsons to provide procurement management and process engineering design for the Lonza Biologics Expansion Singapore (LBXS1), its new large-scale mammalian biopharmaceutical production plant in Singapore. Mechanically completed in September 2008, this 270,000-ft² stand-alone facility—the largest and the first of its kind in the region—provides space for manufacturing, quality control laboratories, offices, and office/facility support (workshops, storage, shipping, receiving, etc.). Lonza has contracted 100% of LBXS1’s capacity to Genentech, and Genentech has an option to purchase the facility.
Parsons managed the process design and procurement of more than $60 million of process equipment and systems for this 80,000-liter, large-scale mammalian biopharmaceutical production plant. The process equipment was fabricated, tested, and disassembled in the United States and then shipped to Singapore for reassembly onsite. Our front-end engineering design study for this fast-track project prepared Lonza for the localized design effort in Singapore because this effort was based on our experience with the Lonza Biologics plant in Portsmouth. We also managed the coordination and development of a 3D model between the design teams in the United States and Singapore and the super-skid vendors supporting the coordinated onsite installation in Singapore of high-purity process and mechanical systems.