Astra Zeneca - Expanded Vaccine Production Plant

As a producer of flu vaccines, Astra Zeneca (MedImmune), the biologics arm needed to reinvest in its biotechnology facilities at Speke to meet an increasing demand for its product, Flumist, a novel and unique intra-nasal medicine and to reduce cost. The production process relied heavily on seasonal labour which made it difficult to guarantee product quality and limited product throughput through the facility.  

In response to this challenge, WSP worked collaboratively with the Astra Zeneca operations team and equipment vendors to design, install and validate a new automated manufacturing process that would boost productivity whilst improving product quality. The result was an ISPE Equipment innovation award to the whole project team, which recognized both the exemplary team work as well as the game changing use of new technology within a highly regulated environment.  

“One of the big challenges was the need to work closely with vendors to develop automation solutions that were fully compliant with Good Automated Manufacturing Practice standards, which was a relatively new concept at the time for the equipment suppliers,” says Chris Davy, technical director at WSP. “Ensuring that the system, as technically brilliant as it was, was equally as rigorous in terms of its control and its validation was vital. We had our control engineers, our validation people and mechanical engineers working very closely with the designers of that equipment to make sure the install would get MHRA and FDA approval.” 

The innovative technology also required the facility’s existing infrastructure to be upgraded and extended. WSP undertook a multidisciplinary design programme, covering everything from architecture, bio-process and equipment design to the re-engineering of the mechanical, electrical and building services. “As with the adaptation of any pre-existing facility, there are constraints on what can be achieved,” says Parker. “We did a lot of front-end masterplanning, looking at a wide variety of solutions that would help the client attain the level of throughput they desired in order to identify where that sweet spot in terms of cost balance lay.”  

The success of WSP’s masterplan resulted in Astra Zeneca being better able to respond to market demand, significantly increasing the business’s resilience. The results were stark: the refreshed facility increased yields by 50% and reduced rejects by 8%, using 25% less manpower. Moreover, this boost to both quality and productivity gave the client’s R&D team greater flexibility to trial new vaccine products.  

WSP’s own adaptability to unforeseen circumstances was also critical to the project. The sudden advent of the avian flu crisis presented Astra Zeneca  with an important commercial opportunity. Thanks to careful masterplanning, there was enough latitude in the schedule to pause construction, allowing the client to temporarily restart production at the facility without having to extend the build programme.  

We have provided the below list of services for this project:

• Feasibility and Concept design studies. 
• Project management and detailed design for Civil Structural, Architectural, Specialist HVAC, Electrical, Equipment.
• Equipment validation and technical support during construction and commissioning.