How pharmaceutical companies can speed up construction projects
The pharmaceutical construction industry has seen explosive growth, a trend with substantial implications for healthcare industry, and global health outcomes. The COVID-19 pandemic underscored the urgency for swift, scalable drug production, sparking a surge in investment toward new production facilities.
The demand for these facilities shows no signs of slowing; driven by biotech innovation that continually pushes the boundaries of therapeutic solutions and precision medicine.
As the industry advances, pharmaceutical companies must address a critical challenge: how to meet this growing demand while managing the escalating costs and complexities associated with constructing specialised facilities.
Why pharmaceutical construction is surging
Several key factors fuel the need for new, high-tech production facilities. Rising investment in research and development within biotech has intensified demand for specialised production environments capable of meeting stringent quality, safety, and regulatory standards. In Q1 2024 alone, biotech start-ups raised a combined $2.9 billion, and the demand is only expected to increase.
Pharmaceutical facilities must accommodate complex, multi-step processes and serve diverse functions – from manufacturing and packaging to rigorous quality control.
The rapid evolution of biopharmaceutical technology also means production environments must be adaptable to align with evolving industry standards and drug development processes. Unlike traditional industrial facilities, pharmaceutical plants are uniquely complex and often modular – a building method where structures are constructed in sections, or ‘modules’, off-site in a controlled factory environment, allowing for reconfiguration as production needs shift.
Given these demands, building new pharmaceutical facilities can cost billions and typically spans multiple years. The stakes are astronomical, both financially and operationally, making these projects among the most challenging in the sector.
Pharmaceutical construction project complexity
Constructing a pharmaceutical production facility requires specialised expertise to meet strict safety, sterility, and regulatory compliance standards. Every aspect of the design and build process must ensure safety, sterility, and compliance with regulatory frameworks. This includes systems to prevent contamination, such as advanced ventilation and filtration, and the use of carefully selected materials resistant to microbial growth.
Precision is critical. Even minor deviations in construction can have far-reaching consequences, such as costly rework or project delays. For example, modular components must seamlessly integrate with the broader facility while adhering to strict regulatory compliance. Failure to achieve this integration can lead to delays that directly affect time-to-market for life-saving therapies.
Project management in this domain is an additional challenge. Pharmaceutical construction projects often involve numerous stakeholders, from architects and engineers to regulatory bodies and manufacturing experts. Coordination among these groups is essential to ensure timelines are met, quality standards are maintained, and regulatory approval processes are not delayed.
Opportunities and challenges with modular construction
Modular construction is revolutionising the construction industry. By building components off-site in controlled environments, companies can ensure higher quality standards and reduce on-site construction times.
This approach also offers flexibility, allowing facilities to be reconfigured as production demands evolve. For instance, a modular design can be expanded to accommodate new production lines for innovative therapies without requiring an entirely new facility.
However, modular construction introduces its own set of complexities. Integrating pre-built modules into on-site structures demands extreme precision. Design errors, logistical issues, or improper installation can result in significant delays and additional costs.
Ensuring that modular components comply with regulatory standards at every construction stage is essential. Advanced project management tools and robust quality assurance processes are critical to navigating these challenges successfully.
The role of technology in accelerating construction
To address pharmaceutical construction’s inherent complexities, companies are increasingly turning to advanced technologies. Precision data and project controls are changing how these projects are planned and executed, enabling greater accuracy and efficiency.
Digital twin technology
Digital twin technology creates virtual replicas of physical facilities, allowing project teams to simulate and optimise construction processes before breaking ground. By identifying potential issues in the design phase, companies can avoid costly errors and ensure smoother project execution.
Building information modelling (BIM)
Mandated in the UK in 2011, BIM is another powerful tool that enhances collaboration among stakeholders by providing a shared digital representation of the facility. This allows for real-time updates, better communication, and improved coordination across all phases of the project.
Augmented reality (AR)
AR technology enables construction teams to visualise complex designs on-site, ensuring modular components are installed accurately and in compliance with regulatory requirements. These tools are already making a significant impact in this area, reducing errors and accelerating construction timelines.
Advanced analytics and AI
Data-driven insights powered by advanced analytics and artificial intelligence (AI) help optimise project schedules, allocate resources efficiently, and predict potential bottlenecks. These technologies are invaluable for managing the complexity and scale of pharmaceutical construction projects.
The future of pharma construction: Precision and agility
With the rising demand for advanced pharmaceutical manufacturing facilities, the need for precise, efficient construction will only grow.
Precision data and project controls represent a crucial evolution in construction methodology, helping companies avoid costly errors, adhere to schedules, and deliver treatments to market more swiftly.
For pharmaceutical companies, adopting these tools goes beyond operational efficiency.
It is a strategic decision impacting competitiveness, patient outcomes, and revenue potential. Leveraging precision data and advanced project controls enables the construction of state-of-the-art facilities that support the next generation of treatments with unprecedented speed and accuracy.
Though the stakes are high, the right tools undoubtedly provide a clearer path forward.
