Strategic infrastructure planning for life sciences manufacturing facilities

The life sciences manufacturing sector is experiencing unprecedented growth, driven by advancements in biotechnology, the rise of personalized medicine and the need for localized production. However, this growth comes with unique challenges, particularly when developing new manufacturing sites. Critical considerations for life sciences facility projects range from utilities and workforce development to tax policy and grid infrastructure readiness.

Utilities and wastewater management

Power and water utilities are a cornerstone of any life sciences manufacturing facility, yet they present significant hurdles. The pharmaceutical and biotech industries generate complex wastewater that requires advanced treatment systems. Some manufacturing companies have faced challenges requiring citywide upgrades to water and wastewater systems. Conversely, certain facilities are decommissioning on-site wastewater plants due to reduced demand. With water being a critical resource for manufacturing processes, companies must plan for sustainable water usage and treatment solutions.

Ohio greenfield site — city water system upgrade and community mitigation

A health care company’s new building in Ohio requires the city to upgrade the entire municipal water system to increase water supply and sanitary discharge. While a greenfield site presents an opportunity for state-of-the-art infrastructure, the development team needs to work closely with residents to mitigate the impact of a large, complex project on the community. In addition to providing alternatives for traffic mitigation, noise abatement and visual aesthetic considerations, build-out of utilities infrastructure should look to enhance the robustness of existing services such as power and water systems.

For example, at the company’s nutraceutical manufacturing complex being planned in the Great Lakes watershed, existing water supply and wastewater collection systems are being extended to serve the new facility. The local water authority expanded water treatment capacity using an integrated membrane system, enabling blending of finished water by a combination of microfiltration and low-pressure reverse osmosis, along with the preexisting lime softening capacity of river water. The membrane expansion facilities were designed for multiphase build-out. Inclusion of this greenfield site in regional water supply planning triggered installation of the next planned phase to meet project demands. A new dedicated surface water intake option was not considered feasible due to the site’s distance from surface water bodies, and private groundwater wells were not favored due to aquifer thickness and variable well yields.

Wastewater management planning involved developing on-site pretreatment with discharge to a publicly owned treatment works (POTW). Since the complex wastewater flow could be up to 10 percent of the POTW’s average inflow, the on-site pretreatment system design was advanced to support discussions for obtaining an acceptance letter from the POTW. Only one parameter, total dissolved solids (TDS), involved stricter-than-planned-for conditions based on the POTW’s receiving body restrictions. The TDS restrictions involved a regionwide issue, and even though the POTW would be willing to accept up to twice its own discharge criteria, surcharges still applied at or above the limit. The impact on site design was to view equipment and operational decisions through the lens of how to limit generating TDS in wastewater.

Illinois facility — production switch, legacy infrastructure and decentralized wastewater

At an existing operating facility, switching site production has resulted in reduced wastewater generation, both in volume and overall strength. The site offers the opportunity to reposition in-place infrastructure designed for commodity chemicals and large fermentation-based medications to better serve smaller-scale biological therapeutics. By 1975, the confidential pharmaceutical company’s North Chicago site had created pumping stations and pipelines to switch from an on-site direct discharge to Lake Michigan to become a significant industrial user discharging through the North Shore Water Reclamation District to inland rivers. The investment complied with planned regional improvements to lake water quality, which included upgrades to public water reclamation facilities to redirect discharges back to the lake.

Recently, the company explored decentralizing its wastewater collection and treatment functions to better serve localized production hubs. This approach would enable fit-for-purpose pretreatment systems tailored to target specific contaminants while maintaining discharge through the existing legacy infrastructure.

Advanced wastewater treatment technologies

Effective wastewater management in life sciences manufacturing facilities requires a combination of advanced technologies, adaptive infrastructure and strategic planning. One critical approach involves deploying hybrid systems that integrate biological processes such as the moving bed biofilm reactor with membrane bioreactors or reverse osmosis to tackle complex contaminants such as active pharmaceutical ingredients and organic compounds.

These systems are often complemented by advanced oxidation processes, which use hydroxyl radicals to degrade persistent pollutants, particularly when paired with biological treatments. Additionally, vacuum evaporation has emerged as a key method for concentrating wastewater streams, reducing disposal costs while recovering valuable APIs for reuse.

The treatment process typically involves multiple stages. Pre-treatment includes customized steps such as pH adjustment, coagulation or dissolved air flotation to remove oils and solids. Primary and secondary treatment follow, using activated sludge or anaerobic digestion to break down organic matter. Tertiary treatment employs reverse osmosis or nutrient removal systems to eliminate trace contaminants and meet stringent discharge standards.

Modular systems, such as containerized membrane bioreactor units, allow facilities to adapt to variable wastewater volumes and compositions. Sustainability initiatives also play a pivotal role, with strategies like water reuse for non-potable applications — such as cooling systems — reducing freshwater demand. In-house treatment systems minimize reliance on third-party disposal, cutting hauling costs, while anaerobic digestion converts organic waste into biogas, turning waste into an energy resource.

Community impact, regulatory compliance and tax incentives

Regulatory compliance is a top priority for life sciences manufacturing facilities. Adhering to stringent local, national and global standards requires robust systems, including real-time effluent monitoring to ensure continuous compliance. Collaborating with municipalities can further facilitate scalable solutions, particularly as production demands grow or evolve.

Proactive planning is equally critical, as shifts in product portfolios may necessitate redesigning utilities, expanding capacity or decommissioning underutilized systems. Leveraging predictive modeling tools allows companies to align wastewater treatment capacity with anticipated product blends, providing operational efficiency and regulatory adherence.

It is important to understand the products at different plants — based on demand — and how those systems will operate with the product mix, especially if they change. Matching a changing product blend with utilities is a critical consideration for long-term operational flexibility and compliance.

Beyond regulatory considerations, community relations play a vital role in site operations. Noise pollution from equipment such as air compressors can lead to complaints from nearby residents, potentially straining relationships with the surrounding community. To mitigate these issues, companies can implement strategies such as installing acoustic barriers, using quieter machinery or scheduling operations during less disruptive hours. These measures help maintain positive community engagement while minimizing operational disruptions.

To support innovation and offset costs, many states offer attractive tax incentives, including credits and grants designed to draw life sciences companies to their regions. Additionally, federal research and development tax credits provide a valuable opportunity for companies to reduce payroll taxes or operational expenses tied to R&D initiatives.

Workforce development

Life sciences facilities require a highly skilled and diverse workforce, encompassing roles such as research and development specialists, pilot plant operators and front-line workers. However, the industry faces significant challenges in recruiting talent for critical positions like regulatory compliance and process engineering due to an ongoing talent gap. To address this, companies must strategically locate their facilities near robust labor markets to access a steady pipeline of skilled professionals. States like Wisconsin and North Carolina have become hot spots for investment, as companies tap into local talent pools while creating thousands of new jobs.

To bridge the talent gap, partnerships with academic institutions are proving essential. Collaborations with universities and community colleges enable the development of targeted training programs that align with industry needs. For example, initiatives like Massachusetts’ Bioversity program and similar efforts in Missouri are equipping underrepresented populations with skills for bioscience careers while addressing workforce shortages. These programs often include certifications, hands-on training and career pathways that prepare candidates for high-demand roles in biomanufacturing, research and production.

Additionally, companies are rethinking hiring criteria to attract a broader range of candidates. Many are shifting focus from traditional four-year degrees to valuing associate degrees, certifications or equivalent experience for front-line production roles. This approach not only expands the talent pool but also aligns with the growing demand for middle-skill roles in life sciences — positions that require specialized training but not necessarily advanced degrees.

Collaborative planning

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 handle changing product portfolios efficiently. 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.

Developing new life sciences manufacturing facilities requires careful planning around utilities, workforce development, cost management and more. Aligning site selection with workforce availability, local incentives, infrastructure readiness and early collaboration with municipalities helps companies address utility demands effectively while positioning themselves for long-term success in this market.