New Flexible Volume Manufacturing Operation in Research Triangle Park (RTP), N.C.

In 2011, we retrofitted warehouse space located on our RTP campus for use as a disposable hybrid manufacturing facility. This facility uses disposable bioprocess bags in place of the stainless steel vessels in which our therapies are traditionally produced. The benefit of these high-tech bags is that significantly less water and fewer chemicals are required to clean the vessels. For more information about our new disposable hybrid manufacturing facility and what the bioprocess bags will enable us to achieve, please see Product Manufacturing & Lifecycle.

Throughout 2011, we’ve continued to realize water savings through previously launched initiatives, which include:

Intelligent Water Chemistry System in our Cambridge Cooling Towers

Our Cambridge campus heating, ventilation and air conditioning (HVAC) system relies on cooling towers. These towers are water-intensive, representing about half of our water usage on this campus. In 2010, we equipped the cooling towers with an intelligent water chemistry control system, allowing us to more accurately monitor the chemical makeup of the water used in the towers. (The water needs to remain below a certain dissolved mineral content so pipes do not corrode or suffer from mineral buildup.) The intelligent water chemistry system also allows us to cycle water through the HVAC cooling towers more times before bleeding it off. In 2011, the system led to savings of more than $13,000 and 740,000 gallons of water.

Clean-in-Place Acid Elimination and Water Optimization Project in RTP, N.C.

In 2009, we worked to eliminate acid from the cleaning cycles through the manufacturing plant while reducing and optimizing water use. From 2009 to 2011, the results of this effort saved more than 3.4 million gallons of water and $2.3 million in costs from chemical reductions.