Boehringer Ingelheim - New Solids Launch Facility

Objective

To develop a highly flexible and modular solids launch facility within the Boehringer Ingelheim network. The facility needed to support the manufacturing of launch products while integrating state-of-the-art containment technologies. To ensure long-term adaptability, the design was required to accommodate other manufacturing processes easily and provide space for future expansion.

The Challenge

The primary technical challenge was to combine strict containment requirements (OEB4) with a layout concept that ensured operator safety, efficient workflows, and future adaptability. The facility had to optimize space based on equipment and operations while enabling the integration of new technologies without interrupting production.

“Combining OEB4 containment with long-term flexibility required an innovative and forward-thinking approach.”

Results

Development of an extended feasibility study where customer requirements were challenged and integrated into the facility design.

Multi-level layout defined:

• Basement: energy and media supply functions
• Ground floor: manufacturing areas
• First floor: central ventilation systems

Introduction of a “train-concept” to separate production areas from central support areas via personal and material EHS locks.

Optimized room sizes based on equipment and operations.

Building layout and façade designed to enable future process equipment installation with minimal disruption.

Future Outlook & Industry Impact

The new facility provides Boehringer Ingelheim with a highly flexible and modular launch platform, ensuring both operator safety and future adaptability. Its design allows for smooth integration of new technologies while safeguarding continuous operations, underlining Exyte’s expertise in delivering complex pharmaceutical facilities.

*This work was completed by Pharmaplan, now part of Exyte