As the demand for peptide ingredients in medicines rises, Bachem is taking significant steps to expand its production capabilities. This growth is not merely about new infrastructure and equipment—it involves navigating a more complex manufacturing landscape while maintaining a high standard of excellence.
Sebastian Hartmann, VP of Manufacturing at Bachem Bubendorf in Switzerland, and Upinder Singh, VP of Production at Bachem San Diego in the USA, provide their perspectives on how the company is scaling up operations while staying true to its core competencies.
The Impact of Growth on Manufacturing and the Transition to Large-Scale Production
Sebastian: Over the past two years, our manufacturing division has undergone substantial changes. We’ve increased our team from 200 to 450 employees and are operating at near-full capacity. This expansion brings challenges, such as commissioning complex systems and introducing new shift schedules to maximize output. However, the transformation is driven by strong teamwork across departments, especially between production and engineering.
Upinder: In the USA, Bachem Vista focuses on manufacturing at scales ranging from 25 kg to 250 kg, serving clinical and early commercial customers. Additionally, Vista supports other Bachem sites with GMP manufacturing capacity, ensuring flexibility and business continuity across our global network.
Process Enhancements to Support Growth
Sebastian: To meet the growing demand, we’ve adopted 16/7 and even 24/7 shift systems to maximize production. Our approach has also evolved to increase efficiency and profitability, with a strong focus on cross-divisional collaboration to address bottlenecks, reduce downtime, and integrate new technologies.
Upinder: Safety, quality, and communication are central to our growth strategy. We’ve made significant capital investments, improved daily production meetings, implemented lean workplace principles for better organization, and thoroughly assessed our manufacturing suites and chemical storage. These steps help streamline processes and maintain efficiency at larger production scales.
Preparing Employees for Large-Scale Production Expansion
Sebastian: With an increased pace of operations, quick decision-making is crucial. We’ve introduced specialized training courses for shift supervisors to prepare them for high-pressure situations. Close cooperation among teams and central functions has been essential in ensuring smooth operations during this growth phase.
Upinder: In San Diego, we emphasize ongoing training to prepare our team for large-scale production. This includes routine cGMP training, as well as education in Value Stream Mapping, lean manufacturing, and tools like Minitab for operational excellence. These initiatives keep our team agile and effective as we scale up.
Maintaining Quality Standards Amid Increased Demand
Sebastian: Quality remains at the core of our operations. We’ve strengthened our training programs to minimize errors and conduct daily floor meetings to discuss quality metrics and resolve issues. Our division also takes part in cross-functional improvement initiatives to ensure quality consistency throughout production.
Upinder: Scaling up doesn’t mean compromising on quality. We rely on standardized processes and equipment to maintain consistency. Regular audits, both external and internal, help us identify areas for improvement and continuously enhance our quality standards.
Committed to Excellence in Peptide API Manufacturing
As Bachem continues its expansion, both Sebastian Hartmann and Upinder Singh stress a shared vision: growth without compromise. By investing in innovative processes, comprehensive training, and fostering a culture of collaboration, Bachem ensures that quality, safety, and efficiency remain central to its operations. As the demand for peptide APIs grows, the company’s dedication to operational excellence, spanning Switzerland and the USA, positions it to overcome the challenges of large-scale manufacturing while upholding its core values of quality and innovation.
Scaling up is not just about producing more; it’s about refining processes to improve efficiency, streamline efforts, and consistently pursue excellence.
