Bayer AG – New injectable manufacturing area with 2 liquid filling lines

Technical and commercial lead of the full lifecycle in all construction areas (facilities, clean utilities (WFI, clean steam, clean compressed air, etc.), black utilities (plant steam, cooling water and compressed air), critical utilities, architectural, mechanical, electrical, HVAC, clean room) and process automation (filler lines, washer, isolators, capper, packaging,)
• Communicate, plan, and organize effectively with colleagues, staff, management, architects, engineers, outside contractors and regulatory agencies
• Manage a variety of projects at one time and bring them to completion on time, under budget, and safely
• A new sterile injectable manufacturing area will be constructed in Leverkusen for Bayer Pharma Healthcare with modernization of an existing plant by demolition and restructuring the existing architectural environment completely to fit to the scope with objective of transferring aseptic filling, including terminally sterilized filling.
• Brownfield project
• The manufacturing area will consist of the following major components:
• Dedicated parts and stopper preparation area with washing machine and vacuum autoclave
• Two liquid filling lines and one liquid / lyophilizer filling line (freeze dryer), using isolators and VHP technology
• Integrated vial washers and depyrogenation tunnels on all filling lines
• Integrated capping with vision system
• Lyophilizer loading and unloading
• Laboratory
• The project budget is 350 m Euro
• Lead of 55 direct employees / contractors
• Project has been completed within time and budget