Baxter, Biologics Manufacturing

Round Lake, IL

Exterior, Baxter manufacturing facility, Illinois


The Drug Delivery Building at Baxter’s Round Lake, IL, campus was the site of an expanded biologics manufacturing facility. A biologics warehouse project followed. GBA provided MEP/FP/specialty gases design for expanded manufacturing capabilities and related infrastructure and staff facilities. The firm collaborated with Norcon for the biologics work (cost, schedule, and constructability consulting).

Expansion and Renovations, Design

GBA has been working at Baxter’s Round Lake campus since 1997, including multiple projects involving the Drug Delivery Building. This project comprised an addition of about 28,000 square feet to increase the company’s manufacturing capabilities for biologics.

  • The scope included employee locker and toilet rooms; a refrigerated product storage and staging area; tank rooms; a filling room; inspection rooms; a pasteurization room; an incubation room; and warehouse rooms.
  • Related utility system upgrades involved new or expanded equipment for distilled water (provided by a replacement still), process compressed air, pure steam, nitrogen, and hydrogen peroxide.
  • HVAC requirements encompassed new supply, return, and exhaust air systems; chilled water, steam, condensate, and cooling tower piping; a new hot water heating system; and a DX cooling system for refrigerated product storage.
  • Related plumbing, fire protection, controls, and electrical expansions and upgrades were also provided, including a new emergency generator, transfer switches, and distribution system.
  • During the project, process design changes were made, requiring addition of cooling systems for eight jacketed process tanks. Additional design changes were also made for the final inspection and packaging facilities.
  • Five years after the initial project, GBA designed a 16,000-square-foot expansion of the campus’ biologics warehouse, creating rack storage space for raw materials and drug products.

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