Design and build of a new mRNA facility in Darlington
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.
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.
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
Director of Biologics and the RNA Centre of Excellence
CPI
“This new centre is an essential asset for scaling up the UK's ability to develop new vaccines and therapeutics, safeguarding us against future health emergencies. These new techniques for developing treatments could provide the UK, and the world with the ability to make life-changing improvements to patient outcomes. ”
