2024 ISPE FOYA Category Winner for Social Impact: Chugai Pharma Manufacturing Co., Ltd.

UK4 Project Overview

The UK4 facility is a 40,000-square-foot marvel specifically designed for the manufacture of early-stage investigational medicinal products. The facility comprises a four-floor production building: the first floor houses office space and material storage, the second and third floors are dedicated to manufacturing areas, and utilities are located on the fourth floor and roof. The culture room features bioreactors with capacities of 50, 500, and 2000 liters, including two production-scale 2000-liter single-use bioreactors.

Innovative Sustainable Solutions

To achieve its ambitious sustainability goals, the UK4 project implemented several innovative solutions:

1. Zero Halogenated Hydrocarbons: Instead of traditional halogenated hydrocarbons, the facility uses naturally occurring coolants like NH3 and CO2. Cooling is provided by ammonia chillers, while heating comes from CO2 heat pumps.
2. Zero Natural Gas: The facility employs electric boilers to supply steam, thanks to several design choices that reduce steam demand. These include using CO2 pumps as heat sources, maximizing single-use equipment to eliminate the need for cleaning and sterilization, and adopting a membrane-based cold WFI system instead of distillation-based equipment.
3. Zero CO2 in Non-GMP Areas: The facility reduces energy consumption and generates necessary power from renewable sources. Solar panels are installed on the roof and integrated into the building’s façade. The northern façade features movable louvers optimized to block direct sunlight while redirecting natural light into the clean rooms. Additional energy management solutions include adjusting room air changes based on load and controlling lighting based on occupancy.

Water Reuse Strategy

UK4 also implements a comprehensive water reuse strategy, recovering rainwater, HVAC condensate, and production wastewater to minimize water consumption and the energy required for production. A centralized energy and environmental monitoring system ensures proper operation and validates efficiency.

A Model for Sustainable Design

The UK4 project stands as a model for sustainable design in pharmaceutical manufacturing. By employing interconnected and innovative solutions, Chugai Pharma Manufacturing Co., Ltd. has created a greenhouse-gas-free facility poised to manufacture the potential medicines of the future.

For these outstanding achievements, ISPE proudly recognizes Chugai Pharma Manufacturing Co., Ltd. as the 2024 ISPE FOYA Category Winner for Social Impact.

Recognition and Achievement

The recipients of the 2024 FOYA category awards will receive formal recognition during the 2024 FOYA Banquet and Awards Celebration in Orlando, Florida, USA, scheduled for Sunday, 13 October 2024. This banquet, held as part of the 2024 ISPE Annual Meeting & Expo, will include acceptance speeches by the awardees, keynote sessions led by prominent industry figures, and ample networking opportunities with pharmaceutical manufacturing and engineering professionals. 

Register for the 2024 ISPE Annual Meeting & Expo and FOYA Banquet and Awards Celebration.

Read more about this recognition in the following article.

About the ISPE FOYA Program

Established in 2005, the Facility of the Year Awards (FOYA) recognize state-of-the-art projects utilizing new, innovative technologies to improve the quality of products, reduce the cost of producing high-quality medicines, and demonstrate advances in project delivery. The FOYA program provides a platform for the pharmaceutical science and manufacturing industry to showcase its accomplishments in facility design, construction, and operation, while sharing the development of new applications of technology and cutting-edge approaches. 

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