Scaling Up Peptide Manufacturing: Expanding Production Capacity to Meet Rising Demand
The global peptide manufacturing industry is undergoing a transformation, driven by the increasing demand for active pharmaceutical ingredients (APIs) used in innovative diabetes and obesity treatments. As pharmaceutical companies race to develop and distribute these groundbreaking medications, the industry is facing a pressing challenge: insufficient production capacity. To address this shortfall, both drug manufacturers and API suppliers have initiated large-scale expansion projects to boost production capabilities and meet market demands.
Bachem’s Strategic Approach to Network Expansion
Bachem, a global leader in it’s manufacturing, has adopted a comprehensive network strategy designed to meet diverse customer needs across various production scales. By optimizing existing sites and constructing new facilities, Bachem aims to expand its API manufacturing capacity and strengthen supply chain resilience.
Expanding Large-Scale Manufacturing
To support growing demand, Bachem is enhancing production capacity at multiple locations:
- Bubendorf, Switzerland: The company’s headquarters is undergoing expansion to accommodate large-scale manufacturing requirements.
- Sisslerfeld, Switzerland: A new, state-of-the-art production site is being developed to further enhance capacity in the medium term.
- Vista, United States: Significant upgrades are being implemented to support production volumes of up to one metric ton.
Scaling for Smaller Production Volumes
For customers requiring smaller API volumes, Bachem has tailored its network strategy accordingly:
- Torrance, United States: This site is optimized for lower production volumes, equipped with the right-scale manufacturing infrastructure.
- Vionnaz, Switzerland: This facility plays a key role in refining expertise in amino acid derivatives, which serve as essential building blocks for it’s synthesis.
- St. Helens, United Kingdom: Specializing in research chemicals, this site continues to develop cutting-edge solutions for diagnostic synthesis.
Building K: Advancing Peptide & Oligonucleotide Production in Bubendorf, Switzerland
One of the most critical developments in Bachem’s expansion strategy is the completion of Building K, a high-tech facility dedicated to large-scale peptide and oligonucleotide manufacturing. Given the increasing global demand for these essential pharmaceutical components, Building K is set to become a cornerstone of Bachem’s production network.
Key Features of Building K:
- Scalable Production Cells: These advanced synthesis units enable efficient API manufacturing at different scales.
- Cutting-Edge Energy Systems: The facility incorporates modern heating, cooling, water management, and cold storage solutions to enhance operational efficiency.
- Specialized Tank Farm: Designed to handle large-scale peptide synthesis, ensuring seamless raw material supply and waste management.
Construction for Building K began in 2021, with the project evolving to meet the growing needs of long-term pharmaceutical partners. The facility is expected to significantly increase peptide production capacity, reinforcing Bachem’s position as a market leader.
TIDES Growth and Expansion at Vista, United States
The Vista site is undergoing a strategic expansion to address the surging demand for peptides, particularly for therapeutic oligonucleotides (TIDES). This initiative will enhance large-scale manufacturing capabilities through infrastructure and process improvements.
Key Enhancements at Vista:
- New SPPS Reactors: These large-scale solid-phase peptide synthesis (SPPS) reactors will improve efficiency in peptide production.
- Cleavage Equipment Train: The addition of two new filter dryers will streamline the peptide purification process.
- Expanded Tank Farm & Waste Management: Increased capacity to support high-volume operations while maintaining environmental sustainability.
- Automated Glass Washer & Upgraded Heating/Chilling Systems: These enhancements will optimize operational efficiency and reduce downtime.
With an aggressive timeline in place, Bachem aims to nearly double its annual peptide output at Vista, ensuring a reliable supply chain for its global pharmaceutical customers.
A Major Swiss Expansion: The New Sisseln Facility
Bachem’s existing production facilities are nearing full capacity, necessitating the development of a new large-scale manufacturing site in Sisseln, Switzerland. This project represents one of the most ambitious industrial expansions in the country, aimed at securing a long-term supply of peptides for the pharmaceutical sector.
Project Scope and Objectives:
- Dedicated Large-Scale Manufacturing: The Sisseln site will be purpose-built to handle high-volume peptide production.
- Advanced Project Management: Leveraging lessons from previous large-scale builds, the project applies new methodologies to ensure efficient execution.
- Long-Term Market Support: The facility will be instrumental in meeting the industry’s increasing demand for high-quality peptides over the next several decades.
Conceptual design for the Sisseln expansion commenced in early 2024, marking the beginning of a multi-phase development plan. Once operational, this facility will play a crucial role in reinforcing global API supply chains.
Expanding Diagnostic Peptide Capabilities at St. Helens, United Kingdom
Peptide synthesis for diagnostic applications presents unique challenges, particularly in maintaining quality and efficiency at high output levels. At the St. Helens facility, Bachem has embarked on a transformative initiative in collaboration with an in-vitro diagnostic (IVD) partner to expand its peptide synthesis capabilities.
Key Achievements in St. Helens:
- Infrastructure Upgrades: Enhancements to peptide synthesis equipment have enabled higher production volumes.
- Refined Synthesis Methods: Process improvements have led to increased efficiency and product consistency.
- Doubled Output: As a direct result of these efforts, Bachem has successfully doubled its production of diagnostic peptides.
This strategic expansion reinforces Bachem’s commitment to innovation in diagnostic peptide manufacturing, supporting the growing need for high-quality reagents in medical diagnostics.
Conclusion: Scaling Up for the Future
As the demand for peptides continues to surge, Bachem is taking bold steps to expand capacity, optimize production efficiency, and strengthen its global supply chain. With major investments across Switzerland, the United States, and the United Kingdom, the company is well-positioned to meet the pharmaceutical industry’s evolving needs.
Through its network strategy, state-of-the-art infrastructure, and commitment to technological advancements, Bachem is paving the way for the future of peptide manufacturing—ensuring that life-saving medications reach patients worldwide without supply constraints. These expansions mark a significant milestone in the industry’s ability to scale up API production and support the next generation of peptide-based therapies.
