NewAge Industries

As the global pandemic was intensifying, there was a crucial need to escalate the production of medical supplies. NewAge, under the US government’s Operation Warp Speed initiative, expanded its production capabilities, primarily focusing on medical-grade disposable tubing. This tubing became essential to cater to the growing requirements in drug and vaccine manufacturing.

Genesis was contracted to renovate and enhance NewAge’s secondary site, an integral extension of their primary manufacturing facility, to ensure seamless and increased production.

The facility was earmarked for the production of single-use thermoplastic tubing products. Understanding the significance and the delicacy of the products, an 18,000 SF dedicated area was designed. Within this space, Genesis installed seven ISO 7 cleanrooms. These cleanrooms were equipped with top-tier HEPA filtration systems. Such a design ensured that the air cleanliness standards were maintained at an optimal level, allowing no more than 10,000 particles per cubic foot.

Apart from the specialized manufacturing area, the site also integrated warehousing and support spaces. These additional spaces were strategically designed to enhance NewAge’s operational workflows, leading to a significant increase in their overall efficiencies.

Challenges Overcome

1. Pandemic-era Restrictions: Launching such a pivotal project during a global pandemic was not without its challenges. With disruptions in the supply chain, unpredictable material lead times, and fluctuating contractor availability, the scenario was less than ideal.
2. Old Infrastructure: Adding to the complexity, the facility chosen for the renovation was a warehouse from the late 1980s. This meant dealing with outdated and potentially deteriorating electrical systems. Comprehensive electrical upgrades became a necessity to ensure the facility met modern standards.

However, in spite of these multifaceted challenges, Genesis’ team showcased their commitment and expertise by completing the entire design and construction process in an impressive span of 18 months.

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Glossary

• Operation Warp Speed: A US government initiative aimed at facilitating and accelerating the development, manufacturing, and distribution of COVID-19 vaccines, therapeutics, and diagnostics.
• ISO 7 Cleanroom: A controlled environment with a specified level of particulate contamination, defined by the number of particles per cubic meter at a specified particle size. In an ISO 7 cleanroom, the air cleanliness is maintained to have no more than 352,000 particles sized 0.5μm or larger per cubic meter.
• HEPA Filtration: High-Efficiency Particulate Air (HEPA) filters are devices that trap harmful particles such as pollen, dust mites, and tobacco smoke.