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Vinta Bio

Viral Vector Plant

Genesis designed and constructed a viral vector biomanufacturing facility to support clinical and ultimately larger-scale manufacturing, in an existing 23,000 SF space at the Philadelphia Navy Yard. Time was of the essence, and occupancy of the facility was phased to meet project requirements.

The initial goal was to design and build a pilot plant that allowed for up to three concurrent productions (mostly Lenti or AAV vectors). However, based on market demand, we later worked with the client to ensure it met future growth with larger scale manufacturing capability.

The client’s process includes varied unit operations including adherent cell process in roller bottles and cell factories, vial filling, and a production scale less than 50L. With that in mind, we incorporated flexibility into our design for easy adaptation.

We constructed the facility to meet FDA and EMEA requirements, while keeping costs as low as possible within an expedited timeframe. We used lean methodologies such as pull-planning, Just-in-Time (JIT) deliveries, pre-fabrication and modularization in order to meet the aggressive schedule.