Plasma Fractionation Manufacturing Facility

Takeda’s greenfield 1.1-million-square-foot plasma fractionation facility near Covington, Georgia is the cornerstone of a global strategy to ensure worldwide delivery to patients through an integrated network that includes plasma donor centers, plasma testing laboratories and manufacturing facilities in multiple countries. Planned within a 160-acre site, this state-of-the-art manufacturing facility fully integrates the technical requirements of both upstream and downstream manufacturing while achieving optimal adjacencies between process areas and creating an environment that positively impacts the wellness of employees. The integrated campus and facility master plans incorporate flexible expansion strategies, enabling incremental or substantial increases in production capacity should market demand continue to rise.

The project emerged from an unprecedented collaborative effort of subject matter experts from around the world, including three major design firms, two major construction managers, two major automation suppliers, a program manager and a prime commissioning, qualification and validation contractor as well as 250 subcontractors.

CRB provided the process, process utilities and process control design across the manufacturing facilities and the central plant. CRB also provided process programming and input on the Current Good Manufacturing Practice flows for the layout of the manufacturing spaces and overall site arrangement. The adjacencies of manufacturing buildings, utilities and warehouse functions were critical to efficient and successful process operations.

This manufacturing facility serves as an industry benchmark for safety in project execution, and Takeda remains committed to the same values despite being the fourth corporate entity involved in the execution of this project after Baxter, Baxalta and Shire.

The project received the 2015 Construction Industry Safety Excellence Award by the Construction Users Roundtable for excellence in construction industry safety performance.

In 2019, this facility was recognized by the International Society for Pharmaceutical Engineering’s Facility of the Year Award judging panel as a 2019 Honorable Mention Winner. The program recognizes state-of-the-art projects using new, innovative technologies to improve the quality of products, to reduce the cost of producing high-quality medicines and demonstrate advances in project delivery.