Seamless incorporation of single-use equipment allows maximum flexibility.

Modular, mobile equipment assemblies – including single-use bioreactors, detergent treatment units, chromatography, and filtration systems – ready for multiproduct manufacturing.

Get in touch

From concept to qualification. ZETA delivers full-scope expertise.

The customer established a state-of-the-art facility encompassing laboratories and manufacturing areas dedicated to the development and production of gene therapy products. Serving as the process integrator, ZETA delivered comprehensive EPCV services – Engineering, Procurement, Commissioning, and Verification – across key operational zones, including upstream and downstream processing, buffer and media preparation, and process development.

ZETA assumed full responsibility for project execution, encompassing project and engineering management, process and mechanical engineering, automation, and qualification.

The challenge

The design of the multi-product facility must meet the need for maximum flexibility in equipment positioning. The connectivity of the SU equipment is an essential factor in ensuring the functionality of the system during changeovers. The production environment, especially the hose and tubing, EIC and automation systems, must be able to seamlessly integrate the SU components to ensure smooth and error-free production.

The solution

Supplier-agnostic integration

ZETA implemented a supplier-agnostic concept, integrating single-use (SU) equipment and connectors from various manufacturers. Compatibility with SU assemblies was thoroughly ensured, enabling full system functionality and production in line with the customer’s stringent standards.

Flexible equipment positioning

To support multiproduct manufacturing, the pilot plant was designed with maximum flexibility in mind. It featured bioreactors, detergent treatment units, chromatography, and filtration systems. These were prefabricated as modular skids at ZETA’s workshop in Moravany. Following a successful Factory Acceptance Test (FAT), the system was delivered, installed, and commissioned at the customer’s site in Belgium.

Modular and mobile assemblies

The use of modular, mobile equipment assemblies allows for rapid adaptation to varying production needs. In the downstream process, for instance, filtration units of different sizes can be deployed to match specific product volumes, ensuring both scalability and efficiency.

Optimized routing of single-use hoses

ZETA developed well-structured routing concepts for SU tubing, ensuring safe, operator-friendly hose management. This approach not only enhances the facility’s visual organization but also eliminates trip hazards, contributing to a safer and more efficient working environment.

Modular and mobile equipment units enable swift adjustment to changing production requirements.

Mobile skids including a vessel on wheels

The multi-product facility is designed for maximum flexibility in equipment positioning.

Detail from skid, consisting from piöes, hoses, valves

The design ensured full system functionality and compliance with the customer’s strict standards.

Mobile skid for gene therapy production, showing an open EIC cabinet and a bottle connected with several hoses

Prefabricated at ZETA’s Moravany workshop, the modular skids passed FAT and were then delivered, installed, and commissioned on-site.

Front section of production vessel, showing screws and a measuring device

The system design ensured operational reliability and adherence to quality requirements.

Turn your vision into reality – start a project with us.

Get in touch Get in touch

Matthias Goriupp

Director Business Line Customised Systems

First name*

Last name*

E-Mail address*

Company*

Land*

Website

I would like to receive regular information and electronic advertising and agree that my data may be processed and used for this purpose by all companies of the ZETA Group worldwide.

zeta.com is committed to protecting and respecting your privacy, and we’ll only use your personal information to administer your account and to provide the products and services you requested from us. By submitting, I agree to the Terms of Use and the Privacy Policy.

Message*

Discover more success stories.