By Justin Ruby, PE, Senior Principal, Mainstay Engineering Group, Inc.
The life sciences and pharmaceutical industries are undergoing transformative shifts driven by rapid technological advances, changing regulatory landscapes, and increased demand for innovation. As an engineering firm with 22 years of experience in these mission-critical sectors, Mainstay Engineering has had the privilege of not only witnessing these changes but also actively driving them, and continuously adapted to meet the evolving needs.
In this article, we explore the key trends shaping life sciences and pharmaceutical facilities today and how they are setting the stage for the future.
1. Modular Construction and Prefabrication
One of the most significant shifts in the design and construction of life sciences and pharmaceutical facilities is the rise of modular construction and prefabrication. This trend is driven by the need for speed, flexibility, and scalability. Modular facilities allow companies to expedite the construction timeline by assembling pre-built modules off-site and then transporting them for rapid on-site installation. This reduces construction times, minimizes on-site disruptions, and allows for easier future expansion or modifications.
A study by McKinsey found that modular construction can accelerate project timelines by up to 50%, while also cutting costs by 20%. For an industry focused on time-to-market for critical medicines and therapies, this speed and efficiency are game changers.
2. Sustainability and Energy Efficiency
Sustainability has become a critical priority across all sectors, and life sciences and pharma are no exceptions. Facilities are increasingly being designed with energy-efficient systems, green building materials, and waste reduction strategies to meet both regulatory requirements and corporate sustainability goals. Incorporating renewable energy sources such as solar and geothermal, along with advanced HVAC systems that reduce energy consumption, is becoming the norm.
Research from the International Energy Agency (IEA) highlights that adopting sustainable practices in industrial facilities can reduce energy costs by up to 30%. Given the energy-intensive nature of pharmaceutical manufacturing, the move toward greener, more efficient operations is both an environmental and financial imperative.
3. Automation and Smart Facilities
The integration of automation and digital technologies in life sciences facilities is another major trend shaping the future. From robotic process automation in manufacturing to smart sensors that monitor environmental conditions, automation is driving greater precision and operational efficiency. These technologies allow for real-time monitoring, data-driven decision-making, and predictive maintenance, which significantly reduce downtime and enhance product quality.
According to a 2023 report by Deloitte, over 60% of pharmaceutical companies are investing heavily in automation, particularly in their R&D and manufacturing processes. This adoption of smart technologies ensures that facilities are not only future-proof but also capable of meeting stringent regulatory requirements.
4. Flexible and Adaptable Facilities
The rise of personalized medicine, cell and gene therapies, and biologics is transforming the types of spaces needed in pharmaceutical facilities. Unlike traditional, large-scale production facilities, these new therapies require more flexible, adaptable spaces that can accommodate smaller batch sizes and specialized equipment.
The shift towards adaptable facilities also reflects the growing need for multi-product, multi-use spaces that can pivot quickly as new therapies emerge. For engineering firms like Mainstay, designing flexible spaces that are easily reconfigurable without significant downtime or cost implications is critical to supporting the fast-paced innovation within the life sciences sector.
5. Resilience and Redundancy in Mission-Critical Infrastructure
Life sciences and pharmaceutical facilities must meet the highest standards for resilience, especially in the wake of global disruptions like the COVID-19 pandemic. The focus on resilience includes ensuring robust mechanical, electrical, and plumbing (MEP) systems, as well as redundant power and water supplies to prevent any operational downtime. As manufacturing becomes more globalized, the ability to maintain uninterrupted operations in the face of supply chain challenges or extreme weather events is essential.
Mainstay Engineering: Your Trusted Partner in Life Sciences, Pharmaceutical & Biotechnology Facilities
With over two decades of experience working within the life sciences and pharmaceutical sectors, Mainstay Engineering Group is uniquely positioned to navigate the complexities and demands of these industries – a testament to why our clients trust us as their Civil and Structural Engineering partner time and time again.
“Our clients are facing increasing pressure to create flexible, compliant, and efficient spaces that can adapt to both immediate and future needs. At Mainstay, we’re seeing a growing demand for facilities that support scalability while meeting stringent regulatory standards and compressed time-to-market schedules – challenges we’re well-prepared to tackle.” -- Justin Ruby, Senior Principal, Mainstay Engineering Group, Inc.
Here’s why Mainstay is the right partner to help with these challenges:
- Deep Industry Expertise: We have a proven track record of delivering engineering solutions for some of the most complex life sciences and pharmaceutical projects, from R&D labs to large-scale manufacturing plants.
- Customized Solutions: We understand that no two projects are alike, which is why we provide tailored solutions that reflect the specific needs of each facility. Whether it’s implementing sustainable systems or designing flexible spaces for future adaptability, we prioritize your unique operational goals.
- Commitment to Innovation: Staying ahead of industry trends is part of our DNA. We continuously invest in new technologies, such as Building Information Modeling (BIM) and smart facility design, to deliver future-ready solutions that optimize efficiency and reduce costs.
- Sustainability at the Core: With sustainability increasingly at the forefront, we are committed to designing facilities that not only meet regulatory standards but also help clients achieve their long-term sustainability objectives. Our engineers are skilled in integrating energy-efficient systems and materials that reduce both environmental impact and operational costs.
- Proven Reliability: In an industry where downtime can be catastrophic, we focus on creating resilient, redundant systems that ensure continuous operation for our clients, even in the most challenging conditions.
As life sciences and pharmaceutical facilities continue to evolve, the role of engineering firms in ensuring their clients’ success is more crucial than ever. The trends of modular construction, sustainability, automation, and flexible facility design are reshaping the landscape. By partnering with an experienced engineering firm, with a proven track record and deep industry expertise, you can ensure that your facilities are built for today’s needs and prepared for tomorrow’s challenges.
For more information about Mainstay Engineering Group, visit MainstayEngineering.com.