Zoetis, Oral Solid Dosage Production Suite

Kalamazoo, MI

pharmaceutical tablets


GBA worked with architect and structural engineer Ingenii on this project, coming in after an initial phase (Phase 1) had been completed. The new oral solid dosage production suite was created through renovations and additions to an existing building (Building 248) on the Kalamazoo campus of this animal pharmaceuticals company.

Engineering Design

GBA designed this project (Phase 2 of the company’s overall Kalamazoo OSD expansion, with Phase 1 having opened in 2019) to proceed in two phases. The work supports growth in Zoetis’ product offerings, particularly prescription tablet medications for dogs.

  • Prior infrastructure work to ensure capacity for all the new OSD production included a new, GBA-designed 8,000-square-foot utility building holding a new 2,000-ton chilled water plant, 15kV site electrical service, and a new process compressed air plant.
  • Phase 2A of the OSD expansion includes a new 10,000-square-foot, single-story maintenance building addition, necessary because some maintenance functions (shops, storage, office space) had to be relocated to make room for the new oral solid dosage line.
  • The Phase 2A addition also houses a metrology laboratory, and allows maintenance personnel to access the controlled production staging areas via a new gown airlock.
  • Phase 2B expanded the OSD manufacturing suite with a two-story, 40,000-square-foot building addition with two separate production spaces and shared tablet-compression rooms; weigh and dispense downflow booth; and material staging.
  • Production spaces include high-shear granulation, fluid bed processing, dust collection, cleanroom design, containment design, and equipment washing.
  • Utilities include a new purified water loop with point-of-use purified water coolers; pharmaceutical compressed air; low-humidity HVAC design; process water; production waste and containment systems; thermal oxidizer; and clean-in-place systems.
  • The engineering design included a 3D coordinated design in Revit.

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