A shift from traditional, static capacity planning to more dynamic, real-time approaches allows for continuous optimization. This is especially crucial as biomanufacturers face the complexities of managing multiple products, varying production schedules and unforeseen disruptions. Additionally, an integrated project delivery method offers concurrent design and construction to accommodate future shifts in process intensity, production throughput, workforce capabilities and regulatory updates. Facility design is no longer just about creating functional spaces. It’s about designing adaptable, future-ready environments that can evolve alongside scientific and technological advancements.

Power and water utilities form the backbone of any life sciences manufacturing facility. The pharmaceutical and biotech industries generate complex wastewater that requires advanced treatment systems. While the historical focus of treating wastewater has been to address immediate impacts, biochemical oxygen demand (BOD) and oxygen depletion, the analysis of longer-term impacts is tied to what is termed as residual, recalcitrant, refractory, or hard to biologically degrade chemical oxygen demand (COD). Residual COD in already treated effluent is considered a proxy for the potential of longer-term environmental impacts from biodegradable resistant compounds such as contaminants of emerging concern (CECs), active pharmaceutical ingredients (APIs), and microplastics and nanoplastics. As such, managing COD removal beyond compliance requirements has become an established key performance indicator (KPI) for some companies. Examples of current corporate initiatives to manage the release of active ingredients into wastewater:

• Recognized Chemical Oxygen Demand (COD) as a key metric for assessing wastewater discharge quality, achieving a 12% reduction from the 2019 baseline by 2023, despite ongoing industrial capacity expansions and transformations.
• Launched a Discharge Quality Improvement Program in 2016 with a goal to reduce effluent COD intensity by up to 70% by 2030, compared with 2012 levels. This initiative is part of a broader integrated water management strategy that also targets water consumption reduction, recycling and addressing water-stress challenges.

While some manufacturing facilities are partially decommissioning on-site wastewater plants due to reduced demand as production shifts to methods generating less wastewater, additional treatment steps may be added to manage residual organics or COD. With water being a critical resource for manufacturing processes, companies planning for sustainable water usage are finding themselves ahead of the trend of wastewater discharge standards moving toward a convergence with reuse requirements and COD reduction solutions.

Successful actions owners can take to manage wastewater include:

• Enhance on-site pretreatment with discharge to the publicly owned treatment works (POTW) to include tertiary treatment for residual COD.
• Select adaptable treatment schemes to allow for switching site production methods at existing operating facilities.
• Decentralize wastewater collection and treatment functions to provide for targeted treatment options of individual wastewater streams.
• Deploy hybrid systems that integrate biological processes with chemical or physical treatment steps.
• Integrate minimum or zero liquid discharge options, such as vacuum evaporation of wastewater into treatment scenarios to provide maximum flexibility.
• Implement advanced biological treatment technologies, such as membrane bioreactors or moving bed biofilm reactors, to efficiently reduce biochemical oxygen demand, chemical oxygen demand and emerging contaminants of concern.
• Adopt real-time monitoring and automation for continuous tracking of critical quality parameters, enabling responsive process adjustments and early detection of upsets.
• Develop water reuse and recycling strategies to reduce freshwater demand, such as reclaiming treated effluent for non-potable uses (boiler feedwater or cooling towers) within the facility.
• Establish partnerships with local municipalities or regional authorities for shared infrastructure investment, ensuring treatment capacity aligns with facility expansions and evolving regulations.
• Prioritize modular and scalable treatment system designs for easy integration of future upgrades or technology advancements, supporting long-term operational flexibility and compliance.

In the face of increasing pressure to reduce environmental impact, sustainability has become an essential focus of biomanufacturing. One area where manufacturers can make a significant impact is in the design of HVAC systems, which are key to maintaining cleanroom environments while minimizing energy consumption. The energy infrastructure of modern facilities must transcend basic reliability and address grid interconnectivity constraints as well as carbon accountability. Some manufacturers are incorporating microgrids, combined heat and power systems, and renewable energy resources to increase resilience and reduce environmental impacts. Predictive modeling tools and scenario-based planning are also being used to simulate how different product lines can affect utility needs, helping facility design systems remain compliant and cost-effective over time. Facilities that can adjust quickly to new products and overall changes will be better positioned for success. 

Anticipating the effects of evolving regulatory criteria and changes in product composition is also central to utility resilience. Utility planning and municipality collaboration must start as early as decisions about building layouts and production processes are being made.

Tax incentives can play a key role in reducing the financial burden of municipal water infrastructure improvements for large-scale biomanufacturing projects. Many states offer infrastructure support grants and tax credits to attract capital-intensive developments, helping cover the cost of water system upgrades needed to serve new facilities. Also, companies investing in research-heavy production may qualify for federal and state research and development tax credits, which can be applied to reduce payroll taxes or offset other operational expenses. When strategically applied, these incentives can improve project feasibility while supporting long-term community infrastructure.

The long-term success of biomanufacturing facilities depends not only on infrastructure but also on access to a skilled and diverse workforce. The industry requires a diverse range of professionals, from research and development specialists and pilot plant operators to frontline production staff. With a persistent gap in talent, companies are rethinking how and where they build their facilities.

Locating facilities within or near robust labor markets can provide a steady pipeline of qualified professionals while creating meaningful employment opportunities for local communities. To deepen that impact, many companies should partner with universities and community colleges to develop targeted training programs that align with the technical needs of life sciences manufacturing. 

While some companies retrofit old facilities for new uses, others are investing in versatile greenfield sites to accommodate diverse product lines. Facilities must be developed and designed to efficiently handle changing product portfolios. This requires flexible utilities and modular systems to support different production demands. Large-scale projects often require municipal upgrades. Companies are integrating renewable energy sources, such as solar or wind power, into their operations to manage utility costs while meeting sustainability goals.

Early planning helps facility owners and their partners consider how all parts of a facility interact with one another and with outside systems. When owners choose to integrate water, wastewater and energy design from the get-go, they are empowered to mitigate future operational risk, thereby reducing capital cost and constructing facilities capable of supporting long-term growth for biomanufacturing developments.