A True Hybrid Facility for Biopharmaceutical Manufacturing

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 detailed cleanroom design, media supply infrastructure engineering, and fabrication of a stainless-steel backbone. The result is a highly adaptable, multiproduct system that demonstrates advanced 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 3D modeling, enabling precise visualization and space optimization. The team also developed custom platforms with integrated tubing and solutions such as 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 14 months, the project followed an ultra-fast-track execution schedule. ZETA’s engineers responded to evolving project scopes and integrated frequent customer change requests. A collaborative project culture was key: ZETA collaborated closely with the client and coordinated with equipment suppliers to support project execution. Customized procurement catalogs supported efficient sourcing, while ZETA’s on-site team coordinated integration across stakeholders. The result was a facility delivered on time and within budget, reflecting ZETA’s expertise in hybrid biopharmaceutical engineering and system integration.