Hybrid Bioprocessing at Scale: Facility Design Challenges for Large Single-Use Equipment
The ever-growing market demand for biopharmaceuticals and the speed to market requirements has ultimately driven an industry need for larger scale single-use equipment. As this equipment has come to market, the challenges around designing facilities around large scale single-use equipment, as well as designing hybrid production trains that must integrate the use of both single-use and multi-use stainless steel equipment, have come into focus. This includes the logistical challenges with single-use consumables of this size, including transport, setup and breakdown, the tubing management challenges associated with larger tubing and longer distances, and many of the idiosyncrasies of dealing with single-use to stainless equipment interface points. Please join us in a joint presentation focusing on these unique design challenges.
1.0 PDH Credit will be awarded for attending this program.
What You'll Learn / Key Takeaways
- Key drivers behind large-scale single-use adoption
Understand how growing biopharmaceutical demand and accelerated time-to-market pressures are shaping facility and equipment strategies. - Designing facilities for large-scale single-use systems
Learn the architectural and engineering considerations required to accommodate larger single-use equipment. - Developing hybrid production trains
Explore best practices for integrating single-use technologies with traditional multi-use stainless steel systems. - Managing single-use consumables at scale
Gain insight into logistical challenges such as transport, storage, setup, and breakdown of large single-use components. - Tubing management strategies
Discover solutions for handling increased tubing lengths, larger diameters, and complex routing over extended distances. - Addressing single-use to stainless steel interface challenges
Understand the technical and operational nuances of connecting and operating across mixed-technology systems. - Design considerations for operational efficiency and scalability
Learn how to anticipate and mitigate design constraints to ensure smooth implementation and long-term flexibility.
Who Should Attend
This session is ideal for biopharmaceutical facility designers and engineers involved in new builds, expansions, or retrofits, as well as process, MSAT, and manufacturing engineers working with large-scale single-use or hybrid production trains. It will also benefit project managers and capital project teams responsible for integrating single-use systems into GMP facilities, along with operations, maintenance, and logistics professionals managing consumables, material flow, and changeovers. Quality, validation, and compliance professionals supporting hybrid single-use and stainless steel environments will find the discussion valuable, particularly those focused on scaling biopharma manufacturing while maintaining speed, flexibility, and regulatory compliance.
Why This Event Matters
This event matters because biopharmaceutical manufacturers are increasingly relying on large-scale single-use technologies to meet growing demand and aggressive speed-to-market timelines. As facilities evolve into hybrid environments, poorly understood design and integration challenges can lead to operational inefficiencies, increased risk, and costly rework. This session provides practical insights and real-world lessons to help teams design more robust, flexible, and compliant facilities, ultimately enabling faster, safer, and more reliable biopharma manufacturing.
Program Agenda:
5:00 - 6:00 PM Networking and Dinner
6:00 - 7:30 PM Presentations
7:30 - 8:00 PM Q&A Session
Speakers:
Lance Briggs — Vice President, ZETA USA
Lance holds degrees in Mechanical and Aerospace Engineering and has dedicated his career to optimizing processes and delivering tailored solutions for the chemical, food, and pharmaceutical industries. With a passion for tackling complex production challenges, he partners with clients to implement cutting-edge technologies that drive innovation and efficiency in their operations.
Todd Rumsey — Discipline Specialist, Jacobs
Todd has over 24 years of multi-discipline design experience in the biotech and pharmaceutical industries. His design experience spans the process, process simulation, automation, and validation disciplines. Todd has 14 years of Jacobs experience working extensively on bulk biologics, ATMP, and RNA/DNA facilities. His skill set includes the design and operation of process equipment such as bioreactors, centrifuges, dead-end and tangential flow filtration, chromatography, clean-in-place, and single-use systems. He has expertise in the optimization of process system and utilities through computer simulation, capacity planning, and the design of intelligent software tools. His experience spans multiple continents including North and South American, Europe and Asia.
MaryBeth Sukenick — Process Architecture SME, Jacobs
MaryBeth has approximately 20 years of experience. She has a wide range of experience that includes a multitude of architypes. The primary focus of her experience includes: pharmaceutical facility design focused in biotech (SS and single-use technology), cGMP warehousing design, packaging facility design, fill finish facility design, with limited experience in semi-conductor facility design. She’s experienced in new facility design as well as complex renovations. MaryBeth has experience with early onboarding trade partners in support of a design assist execution strategy. Her responsibilities include: process architecture programming and conceptual design primarily focused in single-use biotech; small cap bio-tech related feasibility studies; cGMP internal reviews; lead project architect; and owner’s rep. She is comfortable with multiple BIM (building information modeling) platforms as well as other common industry graphics software.
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