This renovation of the vaccine maker’s Kvistgård plant added on-site aseptic fill-and-finish capabilities, allowing the company to stop outsourcing that portion of the manufacturing process. The facility now has the capacity to produce 40 million doses of liquid frozen products and 8 million doses of freeze-dried products per year. 

The team was challenged to fit the addition into former office space and a brownfield on a tight, “landlocked” property, while still creating a facility that would meet FDA and European Union vaccine standards, as well as Danish occupational safety regulations. To overcome the small footprint, they worked with the local municipality to temporarily relax height restrictions during construction. The design ended up being so efficient that there was room left for an additional clinical R&D filling space.