Janssen Biologics vaccine factory, Leiden

Coronavirus vaccines contain a piece of genetic code (mRNA) that is also present in the virus itself. That immediately shows the technical complexity: to develop such a vaccine, you first need a controlled environment—a cleanroom and containment combined—that meets GMP requirements (Good Manufacturing Practice). In addition, the genetically modified organisms must demonstrably be produced according to strict laws and regulations. Simply put, you need an ultra-clean, stable environment where no contamination can enter or exit under any circumstances.

Due to the major societal importance and the extremely fast time to market, everything moved faster than usual from day one. For example, the permit process—which normally takes months—was completed in a single day. Despite an already full portfolio, Kuijpers freed up skilled professionals from all its disciplines for this project. At the request of the vaccine developer, Kuijpers also involved the regular in-house installers. Their extensive experience in managing large multidisciplinary projects proved invaluable. The integrated collaboration between construction site manager SISK, consultant DPS, Van Lith Bouwbedrijf, Kuijpers, and the end user was essential for the fast turnaround of the project.

Kuijpers was responsible for the complete technical installation within the new facility, including thorough commissioning and documentation to ensure the client’s processes demonstrably comply with laws and regulations. Specifically, this involved electrical, mechanical, and control systems, process utilities, a kill tank for wastewater purification, and complete process control. Kuijpers’ engineering expertise in the early phase also played a key role.

Thanks to early contractor involvement, construction work began even before the design was finalized. This effective approach helped ensure that less than a year passed between the first sketch and actual production in the new facility. It was a challenge that sometimes required stepping away from traditional paths without compromising on quality. The result: a prestigious Dutch vaccine factory built to the highest standards. The fact that the project took place during the pandemic—with all the associated safety measures—makes the achievement even more remarkable.