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“Our latest OSD Plant Expansion required a design firm with experience in designing large projects. We found that with the GBA Team,” said Mark Callahan, Zoetis Director of Strategic Projects.
“Since the start of design, the GBA team has provided valuable insight to the facility layout,
system integration, process needs and overall function of the plant. The attention to detail and professionalism of the team has been fantastic and will definitely contribute to the success of the project. It has been a true pleasure working with the entire GBA team.”

– Mark Callahan, Zoetis Director of Strategic Projects

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The Background

Zoetis needed a partner to double their manufacturing capacity for their life-saving chewable product, Simparica Trio, and the new Apoquel Chewable tablet. The project took place at their OSD manufacturing campus in Kalamazoo, MI. The GBA team provided full engineering services including architecture, structural engineering, mechanical engineering, process engineering, electrical engineering, fire protection, and life safety for the design of the 100,000-square foot 3-level greenfield facility. This included 50,000 square feet of manufacturing space, supporting offices, a warehouse, and an 8,000-square-foot chemistry and stability lab. The project had an overall cost of $175 million.

The Design

To ensure a smooth start, the GBA team collaborated with a “lessons learned” meeting in the early stages. During this meeting, the teams discussed what worked and what didn’t work in the site’s existing facility. GBA conducted a thorough analysis of the existing operational process flow and proposed multiple solutions to minimize material movements, eliminate bottlenecks, and reduce the number of staff required.

During the design phase, GBA presented concepts for both renovating the existing building (retrofit) and constructing a completely new facility (greenfield). After evaluating layouts, cost, and construction schedule, the greenfield design was chosen to provide flexibility, improve process flow, and minimize disruption to ongoing operations.

Two separate manufacturing wings, each dedicated to a specific product process, flank a shared central core reducing redundant areas, ensuring product segregation, and allowing for different environmental and humidity conditions for the different products.

GBA established an early partnership with Glatt, the process equipment manufacturer. This collaboration enabled GBA’s process engineers to design the space around the specific equipment intended for the new facility. Facility operators were actively involved throughout the design process to ensure that all aspects of space utilization, including functionality, ergonomics, and durability, were considered.

The Innovation

GBA prioritized efficiency and cost-effectiveness in their designs, aiming to enhance existing processes while also improving safety. As part of their efforts to streamline operations and reduce the handling of hazardous materials, they implemented a bulk ethanol process.

To accelerate the construction timeline, GBA divided the design into multiple packages. These packages included core and shell, long lead equipment, manufacturing fit-out, and lab fit-out. By issuing these separate design packages, GBA aimed to expedite the construction process and ensure efficient coordination between various aspects of the project.

The Future

At GBA, we don’t just design buildings, we design experiences. From the addition of modern warehousing and office space to a state-of-the-art lab, manufacturing and packaging area, our designs for Zoetis’s expansion are setting the bar for the Life Sciences industry. With a standalone electrical substation, purified water generation and distribution, clean and plant steam/distribution and chillers, this specific facility is ready to operate as a standalone manufacturing powerhouse.

Construction for Phase 3 is underway and set to be completed in late 2023, with Phase 4 following.  It’s an exciting time for Zoetis, and GBA is honored to be a part of the journey toward a brighter, healthier future for all our furry friends.