Microbiology/Sterility Test Laboratory

APP Pharmaceuticals needed a new microbiology lab to support aseptic product manufacturing. Design development included the construction of clean rooms and employed isolation technology for sterility testing of product and media samples. Burns & McDonnell provided mechanical design, construction support and startup assistance for this project.

• Mechanical engineering
• Process equipment
• Construction support
• Startup assistance

Once Burns & McDonnell completed component preparation modifications at the facility, APP engaged Burns & McDonnell to provide engineering, construction and startup assistance to renovate an abandoned 30-year-old chemistry laboratory located on the second floor above the current production and laboratory spaces.

The final design for this lab included:

• Pass-through glassware washer
• Pass-through autoclave
• Cold room
• Walk-in incubator
• Class 10,000 sterility test suite with isolators
• Type IIB2 biosafety cabinets
• Water for injection loop, clean steam expansion and utility piping
• HVAC and exhaust systems

The project team performed extensive verification of existing utilities and building conditions, which included reusing a roof-mounted air handling unit, replacing ductwork, adding high efficiency particulate air filters and installing a building management system.

• Completed project safely and on time
• Performed construction without disrupting plant operations
• Realized substantial cost savings by reusing existing equipment
• Performed intricate mechanical design due to spatial constraints