Sustainable wastewater treatment at biopharma site expansion

A global leader in the development and manufacture of vaccines and plasma-derived biotherapies was looking to expand production capacity to help meet growing healthcare needs worldwide. At its manufacturing facility in the Midwestern US, a major expansion created the need for a reliable and sustainable wastewater management solution capable of meeting stringent pre-treatment standards for discharge to the local publicly owned treatment works (POTW).

The client partnered with Ramboll to deliver the wastewater treatment upgrades through a design-build project delivery model that supported expansion while maintaining regulatory compliance and operational continuity.

Designing a wastewater solution for future growth

Ramboll conducted a comprehensive evaluation of wastewater sources across the facility, reviewing historical wastewater characteristics and identifying potential treatment challenges associated with changing production demands. Treatability testing was then performed to verify treatment performance under defined operating conditions and to establish the basis for an optimised treatment strategy that could be advanced directly into design, procurement, construction, and commissioning.

The resulting solution included three integrated components: a wastewater pH neutralisation system, an onsite biological treatment facility designed for nutrient removal, and planning for long-term operations and maintenance. Through detailed process analysis and testing, our experts identified the most effective treatment technologies and developed a system tailored to the facility’s unique wastewater profile, while sequencing delivery to align with ongoing production and site expansion activities.

As prime design builder, Ramboll brought together multidisciplinary expertise in water, advanced manufacturing, environment, and health under a single integrated delivery team. This approach enabled the project to move efficiently from evaluation and design through procurement, construction, startup, and phased integration, helping ensure alignment between technical requirements, project objectives, construction sequencing, and operational needs.

Building resilience into long-term operations

The new treatment system was designed to be both flexible and resilient. Key features included biological treatment processes capable of adapting to variable loading conditions, nutrient balance controls to optimise treatment performance, enhanced solids handling systems, and backup power provisions to improve reliability and minimise operational risk. These elements were incorporated through a phased integration strategy that supported long-term performance while providing the flexibility needed to accommodate future production growth.

The project demonstrates how advanced wastewater treatment and design-build delivery can help manufacturers achieve both operational and environmental objectives. By combining rigorous testing, process optimisation, integrated project delivery, and phased implementation, we developed a cost-effective solution that supports regulatory compliance while helping the client maintain its focus on producing life-saving therapies.

Today, the upgraded wastewater treatment facilities provide the client with a robust and sustainable infrastructure platform that supports continued manufacturing expansion, enhances environmental stewardship, and ensures reliable treatment performance for years to come.