In 2021, Merit proudly partnered with the Centre for Process Innovation (CPI) to deliver a groundbreaking mRNA ‘vaccine library’ Darlington, designed for rapid response to emerging health challenges. As a pioneering social enterprise, CPI plays a vital role in accelerating drug development, offering world-class facilities and expertise in complex medicines like biologics and oligonucleotides.
To deliver this pioneering facility, we deployed our innovative UltraPOD® platform. UltraPOD® is an expandable building solution designed to make advanced manufacturing more accessible and affordable.
Today, the RNA Centre of Excellence stands as the sole UK-based facility capable of developing and manufacturing lipid nanoparticle-encapsulated mRNA vaccines and therapies under one roof, setting a new standard for early-phase clinical trials and providing hope for a healthier future.
- Client: Centre for Process Innovation (CPI)
- Location: Darlington
- Sector: Life Sciences
- Project: mRNA vaccine Library
- Value: £5m
Key Features
– Construction of a £5m mRNA vaccine library facility
– Two-storey facility utilising Merit’s UltraPOD® solution
99.9% project waste was recycled or reused
– Low-carbon design resulting in a facility that is Zero Scope 1 carbon in operation enabled.
Challenges and Solutions
– Navigating COVID-19 Restrictions: Merit embarked on the CPI Project amidst the challenges of the COVID-19 pandemic. Employing a fast-track approach, Merit emerged as the sole contractor capable of meeting the project deadline within stringent pandemic restrictions.
– Efficient Project Execution: The project demanded a rigorous 30-week schedule. Collaborative design workshops, facilitated through digital platforms like Teams, Viewpoint, and Revit, ensured seamless communication and decision-making. Despite the accelerated timeline, efficient engagement of client stakeholders minimised disruptions to their daily responsibilities, crucial in the healthcare and biopharma sectors.
Key Outcomes
– Achieved 80% Pre-Manufactured Value (PMV): This indicates a high degree of offsite manufacturing, significantly reducing on site construction time and labour.
– 50-year facility lifespan achieved through offsite construction, indicating resilient design, better quality control, efficient material usage and precision engineering.
– Rapid, successful commissioning and validation, to reduce project lead times and ensure the facility was in operation faster.
– 8 months project completion, delivered throughout height of COVID-19 restrictions, a time of inflation and material shortages