Sartorius 2022 Yauco Campus Master Plan: A Vision for Growth and Resilience

Location: Yauco, Puerto Rico

Client: Sartorius

Project Overview / The Challenge:

Driven by evolving market demands, including the accelerated production of COVID-19 vaccines under Operation Warp Speed, Sartorius needed to re-envision its 40-acre Yauco Campus Master Plan. The challenge was to explore the campus's full potential to meet immediate and future manufacturing requirements, while preserving architectural harmony and adapting to a rapidly changing bio-pharma landscape.

Our Approach / The PIERI Solution:

As the original architects of the 2016 master plan, PIERI Architects brought deep, intimate knowledge of Sartorius’ operational needs and the campus architecture. We collaborated with Gensler Baltimore and Grean Engineering (Hannover), leveraging our combined expertise in large-scale pharma-biotech facility design, operational efficiency, and local bioclimatic/regulatory conditions. This collaborative approach aimed to balance operational capacity, employee well-being, and sustainability. Despite COVID-19 restrictions, a combination of virtual and in-person workshops ensured continuous progress and team camaraderie.

Key Design Features / Innovations (Master Plan Highlights):

• Operational Expansions: New ISO 7 cleanrooms, laboratories, and high-density warehouses; expansion of membrane manufacturing from 3 to 12 lines; and implementation of ion-beam sterilization for FMT products.
• New Facilities: A centrally positioned office tower and a wellness-focused employee services hub with a canteen, wellness facilities, and landscaped spaces for relaxation.
• Infrastructure Enhancements: A cutting-edge Central Utility Plant with rooftop PV arrays, cogeneration units, and absorption chillers for energy-efficient utilities; a phased infrastructure distribution plan with modular utility cores; and expanded employee parking.

Anticipated Outcomes & Aspirations:

The 2022 Sartorius Master Plan is a dynamic blueprint offering both immediate solutions and long-term flexibility, with phased development projected over the next 5-10 years. Key sustainability goals include:

• Low-Impact Site Development: Emphasizes habitat restoration, stormwater runoff reduction, heat island mitigation, and drought-tolerant native plants.
• Water Conservation: Aims to significantly reduce potable water consumption and promote water reuse through advanced water-saving, harvesting, and processing strategies.
• Energy Efficiency: Goal of a 50% improvement in energy efficiency through efficiency measures, renewable energy, and cogeneration systems.
• Modular and Off-Site Construction: Minimizes waste, reduces construction time, and streamlines processes while maintaining high sustainability standards.
• Health and Wellness: Integrates interior and exterior communal spaces to enhance employee health and well-being, fostering a positive and productive work environment.

This master plan positions the Yauco campus for sustained growth and adaptability, ensuring it meets future challenges by scaling operations while maintaining a steadfast commitment to innovation, sustainability, and employee/community well-being.