Why pharma must think like tech: The case for modular and scalable factories

While the pharmaceutical industry has the inherent disadvantage of requiring significant infrastructure for each therapy, a persistent resistance to change causes organisations to fall short when trying to keep pace with market trends. Modular, production design is an emerging approach that helps pharma companies adapt to market trends more readily, providing a scalable and flexible approach to production. NIRAS is a leading provider of facility design consulting services, helping companies adopt modern, flexible, and future-proof production approaches.

This article will explore the pressing need for flexibility in pharmaceutical production and highlight the benefits companies can expect when they adopt a modular approach.

The pressure on pharma

The pharmaceutical market is rapidly evolving, driven by breakthroughs in personalised medicine capabilities, vaccine development, and shifting regulatory requirements1. Cell therapies, where an individual’s cells are altered and used as a therapeutic agent, provide perhaps the clearest example of personalised medical advances. However, these therapies pose challenges for pharma companies as production must cater to smaller customised batches that do not benefit from the economies of scale associated with conventional medicines (2).

In light of rising demands for speed and market leadership, companies are under increased pressure to deliver efficiency, maintain quality, and uphold compliance. This is far easier said than done with traditional brick-and-mortar plants, which require high CAPEX and long build times to adapt to technological and market changes. This inflexibility also prevents organisations from adapting to global health crises, such as pandemics, rendering them incapable of filling time-sensitive marketplace niches. There is also increased pressure for companies to adopt more environmentally sustainable practices and reduce waste (3) or even implement circular practices. Thus, there is an urgent need for adaptable, cost-effective production methods.

Modularity as a mindset

Though there are obvious differences between the tech world and pharma, a shift in mindset towards modular processes is likely to yield enormous benefits for pharma organisations struggling to cope with rapid change. The tech sector benefits from hardware modularity, enabling companies to exchange components between different systems without the need for rebuilding the entire platform. Individual components can be easily upgraded to meet growing demands or technological advances, such as increased storage capacity or enhanced processing speed. Similarly, modern software is built using microservices, which are small services focusing on a single capability that together form a complete application. Employing microservices in various combinations enables tech companies to achieve a range of functional applications without the need to build each one from scratch.

A similar modular approach in the pharmaceutical industry would enable production plants to be reconfigured and scaled up or down to meet market demands. This approach would offer significant benefits in terms of efficiency, waste reduction, and increased resource efficiency, as production components could be utilised for various tasks rather than going unused when the market shifts away from a particular therapeutic or technological breakthrough that renders it obsolete.

What is a modular production facility?

Modular facilities use standardised, or based on a basic set of requirements, modules with distinct functionalities (4). Modules are fabricated off-site to ensure minimal disruption and can be easily integrated into a production line when needed. Modular process skids are functional units or systems mounted on a support frame that allows them to be easily transported. Standardised, predesigned units cover core plant components such as:

●    Clean water
●    HVAC modules
●    Electronics
●    Vacuum systems
●    Control cabinets

Modular systems are integrated through a unified interface, and their interfunctionality is ensured with smart automation. Standardised connections ensure seamless integrations and flexibility in addition to reliable data capture across all modules. Predesigned modules can arrive prevalidated and tested, meaning they can be instantly placed into existing infrastructure, minimising downtime and the need for extensive onsite validation.

Modular designs have significant advantages over traditional builds, including:

• Lower risk and predictable costs: Standardisation of prefabricated modules ensures businesses have a better understanding of upcoming expenses and module compatibilities.
• Easier regulatory validation due to standardisation: Compliance is simplified by using established modules built to meet regulatory standards.
• Scalability for multi-product facilities: Additional modules can be added, and existing modules can be rearranged or reconfigured to scale up and support multiple production lines.
• Faster construction timelines: Standardisation ensures seamless integration, enabling the rapid construction of complex production lines.

Facility design for Pharma

NIRAS provides expert support for advanced facility design in the life science sector. With a deep understanding of where the industry has come from and where it’s going, NIRAS is optimally positioned to offer expert guidance on production facility design that caters to core functionalities, regulatory requirements, and market demands. This expertise goes beyond ensuring optimal production, providing a holistic approach that caters to the needs of workers and aligns with shared sustainability goals (3). NIRAS engages with clients at all stages, supporting facility design from conceptualisation to execution and providing flexible solutions such as “Dancefloor” layouts. These layouts allow equipment to be rearranged easily and improve the movement of workers and materials, supporting optimal operations.

NIRAS’ expertise and knowledge of the industry allow clients to benefit from:

• Faster time-to-market: Flexibility allows production facilities to adapt more quickly to market trends and regulatory requirements, resulting in more efficient production and reduced risk.
• Reduced capital risk: Flexible workflow designs enable the rearrangement of equipment and workspaces, eliminating the need for organisations to invest in new space or instrumentation to diversify their operations.
• Future-proofing: Flexible workspaces enable pharmaceutical companies to adjust their production more easily in response to unexpected market trends, disruptive technologies, and urgent medical needs, such as pandemics.

Modularity as a competitive advantage

Modular approaches to facility design are a crucial development in the pharmaceutical industry. Regulators are increasingly supportive of modular designs for pharmaceutical production in addition to continuous manufacturing processes (5). This means that adopting modular designs sets companies up for success in the increasingly competitive marketplace with shifting regulatory environments. While modular manufacturing is not immune to obsolescence or regulatory shortcomings, organisations that adopt it are better equipped to respond to shifting trends and can replace non-compliant modules rather than entire production lines. 

Modular approaches support sustainability goals by lowering the carbon footprint of production facilities. Modular approaches allow organisations to reuse and relocate infrastructure, allowing for smaller footprints that reduce facility emissions and lower heating and cooling costs. Standardised module fabrication ensures optimal resource utilisation and less material waste.

Conclusion

Pharmaceutical companies have a fantastic opportunity to learn from the tech industry playbook and adopt modular approaches to their operations. Such approaches will enable companies to remain agile, competitive, and compliant in a constantly evolving regulatory and technological environment. Facility design is complex, especially when new approaches are introduced into well-established processes. Partnering with trusted experts, such as those at NIRAS, gives companies a competitive advantage when adopting modular production designs. Expert consultation, from concept to delivery, ensures that pharmaceutical companies reap the full benefits of modular production, helping them achieve faster time-to-market, reduced risk of non-compliance, and lower CAPEX.

Contact our team today to begin your journey toward greater flexibility and reduced risk with a trusted modular production partner.

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References

1. Dr. Anil Kumar*. Advancements and Challenges in Pharmaceutical Innovation: Navigating Regulation, Technology, and Global Access. Published online March 24, 2025. doi:10.5281/ZENODO.15077292
2. Morotti M, Albukhari A, Alsaadi A, et al. Promises and challenges of adoptive T-cell therapies for solid tumours. Br J Cancer. 2021;124(11):1759-1776. doi:10.1038/s41416-021-01353-6
3. THE 17 GOALS | Sustainable Development. Accessed April 22, 2025. https://sdgs.un.org/goals
4. Algorri M, Abernathy MJ, Cauchon NS, Christian TR, Lamm CF, Moore CMV. Re-Envisioning Pharmaceutical Manufacturing: Increasing Agility for Global Patient Access. Journal of Pharmaceutical Sciences. 2022;111(3):593-607. doi:10.1016/j.xphs.2021.08.032
5. National Academies of Sciences E, Studies D on E and L, Technology B on CS and. CONTINUOUS MANUFACTURING FOR THE MODERNIZATION OF PHARMACEUTICAL PRODUCTION: PROCEEDINGS OF A WORKSHOP. In: Continuous Manufacturing for the Modernization of Pharmaceutical Production: Proceedings of a Workshop. National Academies Press (US); 2019. Accessed June 24, 2025. https://www.ncbi.nlm.nih.gov/books/NBK540224/