Topping-out ceremony for the new Bayer pharmaceuticals plant in Leverkusen (from left): Stefan Oelrich (Head of the Bayer Pharmaceuticals Division), Heike Hausfeld (Chairwoman of the Bayer General Works Council), Bayer CEO Werner Baumann, German Chancellor Olaf Scholz, German Health Minister Karl Lauterbach, Chairman of the Bayer Supervisory Board Prof. Dr. Norbert Winkeljohann, Bayer Board of Management member Sarena Lin, Uwe Richrath (Mayor of Leverkusen), Source: Bayer AG
On May 13, 2022, Bayer AG celebrated the topping-out ceremony for a new pharmaceutical plant in Leverkusen in the presence of German Chancellor Olaf Scholz, Federal Minister of Health Professor Dr. Karl Lauterbach and other guests from politics and business. The new Solida 1 production plant will be one of the most modern pharmaceutical production facilities in the world. The aim is to translate the results of scientific research into products as quickly as possible and thus improve the lives of patients in the long term. Among other things, drugs for the treatment of cancer and cardiovascular diseases will be produced here.
As a system integrator, Glatt was already involved in the concept phase for the process, the process logistics, the process automation and its integration into higher-level systems, and has continued the planning for this itself throughout the various subsequent project phases. The process expert, plant manufacturer and engineering service provider is not only responsible for the delivery, installation and commissioning of Glatt systems, but also for the process equipment of other suppliers.
A key component of the system integration for this project is extensive, highly innovative automation. Intelligent robot technology is being used for the first time in this type of application. This means that all process equipment is integrated into a standardized system that communicates with each other.
The modular structure of Solida 1 – and thus the possibility of extensions, for example – creates the greatest possible flexibility with regard to future developments in the pharmaceutical sector.
“For this exciting task, practically all of Glatt’s expertise in pharmaceutical solids production comes into play, which probably only the Glatt Group can offer. We will certainly still have to face some challenges in the realization of the project. However, we are convinced that we as the entire Glatt Group are up to the task,” said Dr.-Ing. e. h. Reinhard Böber, Managing Director of Glatt Ingenieurtechnik GmbH, during the podium discussion at the topping-out ceremony.
The new modern plant will be the core of the new global competence center for the production of solid pharmaceuticals at the Leverkusen site. It will not only set standards for efficiency, quality, supply reliability and sustainability, but will also take advantage of digitalization with a so-called “learning factory”. This means that data streams are analyzed with the help of artificial intelligence and recommendations for action are derived from this.
According to Bayer, the plant also sets standards in terms of sustainability: its energy requirements are largely covered by a modern geothermal system, which reduces CO2 emissions by 70 percent compared to conventional plants.
The single-storey facility with a gross floor area of around 15,000 square meters is scheduled to be ready for operation in 2024. Around 100 employees will start work in the building. The company’s total investment amounts to around 275 million euros.
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