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In terms of internal rate of return (IRR), modular manufacturing facilities are less expensive than stick-built facilities, with an IRR of 11% versus 8% for stick-built facilities. This provides an excellent opportunity for business partners to optimize project costs
-- CEO, a US-based mid-sized company
The global modular construction market size is estimated to be worth $2.5 billion in 2023 and is expected to grow at CAGR of 10% during the forecast period. In the past few years, modular facilities or prefabricated buildings have emerged as a promising alternative to the conventionally built pharma / biotech manufacturing facilities. Modular construction involves building of structures using prefabricated modular units, off-site, under controlled factory setting, which are later assembled on site. It is interesting to note that off-site construction can eliminate 60%-90% of the weather-related project concerns.
Further, modular facilities can be built 40% faster, as compared to a conventional construction, which could take up to three years. Therefore, considering the various advantages offered by this approach, several pharmaceutical companies are now shifting their focus from conventional plants to modular facilities. Specifically, modular facility providers are catering to the needs of various players engaged in the development of therapeutics, including cell and gene therapy, biosimilars and vaccines.
To provide more context, modular manufacturing includes division of individual production processes, such as fermentation, purification and formulation, into separate modules that can be easily assembled and disassembled, allowing for flexibility and scalability. In addition, modular manufacturing allows the use of smaller-scale production units, which can be more flexible and responsive to dynamic market demands. Moreover, temporary modular buildings can be relocated after installation, based on needs of the end-user. However, mass production, complex decision-making, construction approvals and early financing can hinder the adoption of modular constructs. If healthcare stakeholders are able to overcome these challenges, modular construction can serve as a lucrative approach that provides greater flexibility and enables faster time-to-market for new products.
The Modular Construction Market for Biotechnology and Pharmaceutical Industry (3rd Edition), 2023-2035: Distribution by Size of Facility (Small, Mid-sized, Large and Very Large), Type of Industry Served (Pharmaceutical and Biotechnology), Type of Modular Construct (Hybrid Skid Modular Constructs, Skid-Mounted Modular Constructs, Plug-and-Play Modular Constructs, Truckable Modular Constructs and Other Modular Constructs), Type of Construction Component (Process Equipment, Base Building, Mechanical, Electrical and Plumbing System, Process Commodities and Other Construction Components), Purpose of Facility (Manufacturing Facilities, Aseptic Filling Facilities, Research and Development Facilities and Other Facilities), Scale of Operation (Clinical and Commercial), Type of Product (Cell and Gene Therapies, Vaccines, Biosimilars, Monoclonal Antibodies, Advanced Pharmaceuticals, Sterile Products, Viral Vectors and Other Products), Type of Expansion (New Facilities, Facility Expansions and Planned Expansions), Type of Modular Construction (Relocatable Modular Construction, Permanent Modular Construction), Type of Material Used (Steel, Wood and Concrete) and Key Geographical Regions (North America, Europe, Asia, Middle East and North Africa, and Rest of the World): Industry Trends and Global Forecasts, 2023-2035 report features an extensive study of the current market landscape, market size and future opportunity, offering an informed opinion on the likely adoption of modular manufacturing in the biotechnology / pharmaceutical industry, over the forecast period. The market report features an in-depth analysis, highlighting the capabilities of various stakeholders engaged in this industry. The research report answers the following key questions related to the biopharmaceutical modular manufacturing market.
Modular facilities have emerged as a promising alternative to conventional facilities owing to the multiple benefits that they offer. For instance, modular facilities can help in achieving 25%-30% reduction in the overall cost of construction, minimal plant site interruption, 50%-60% faster construction timelines, as well as ensure portability, safe working conditions and sustainability. In addition, better quality of products can be achieved by modular construction approaches as the modules are built in a controlled factory setting. In addition, these modules are inspected more thoroughly and frequently before they are shipped to the construction site, meeting desired quality standards. Moreover, modular construction allows more flexibility in terms of design, as a higher number of materials and finishes can be used, as compared to conventional facilities.
The modular construction market landscape features an extensive list of over 50 large, mid-sized, small and very small manufacturers. It is worth highlighting that there are more than 250 modular cleanroom manufacturers, offering various cleanroom accessories and customization options, in order to make them suitable for application in the life sciences industry. It is expected that modular manufacturing will become more streamlined and standardized in the future, serving as an efficient cost saving solution. Additionally, modular techniques allow building of smaller and specialized processing plants whenever rapid deployment of a therapy becomes critical in both developed and developing countries. Further, many, if not most, expansions and new facilities in the biotechnology and pharmaceutical industry are likely to be modular construction in the near future.
Over the past few years, several factors have contributed to reform the facility construction paradigm within the pharmaceutical and biotechnology industries. The increasing preference and demand for personalized therapies and novel therapeutic interventions intended for the treatment of various ailments has compelled pharmaceutical companies to look beyond the traditional manufacturing and expansion practices. Lack of adequate manufacturing infrastructure, increased cost of construction and delay in project deliveries has collectively contributed to the emergence of off-site construction models. In addition, the increased demand for vaccine manufacturing during the COVID-19 pandemic also proved to be a key growth driver for adoption of the modular clean room / prefabricated cleanrooms. In March 2021. G-CON Manufacturing delivered its prefabricated cleanroom PODs to Fujifilm Diosynth Biotechnologies for expansion of COVID-19 vaccine manufacturing at its College Station, Texas facility.
Another China based modular facility manufacturer, Pharmadule Morimatsu AB delivered a modular vaccine manufacturing plant in Morocco. Funded by the Moroccan government, the plant was set up to increase the local production of vaccines. Even the growing cell and gene therapy market is adopting modular manufacturing. In May 2022, G-CON Manufacturing supplied prefabricated cleanrooms to Puerto Rico facility of CytoImmune for clinical manufacturing of NK cell-based therapies. Over the forecast period, the realization of the benefits offered by modular manufacturing of drug facilities will drive the modular construction market growth at a CAGR of 10%, as the drug manufacturers realize the benefits offered by modular manufacturing of drug facilities.
Driven by the rising interest of stakeholders towards improvement of manufacturing and production efficiency, the anticipated lucrative opportunities and growth associated with the adoption of modular facilities, the modular manufacturing market for pharmaceutical industry is expected to witness noteworthy market growth during the forecast period. Specifically, in terms of type of product, the market is anticipated to be driven by manufacturing units for cell and gene therapies, as well as vaccines and biosimilars. In addition, presently, close to 70% of the modular construction market share is captured by facility manufacturers based in North America and Europe. However, in the long run, markets in emerging regions, such as countries based in Asia, MENA and rest of the world are anticipated to grow at a faster pace.
Examples of key companies engaged in this industry (which have also been profiled in this market report) include (in alphabetical order) Cytiva, G-Con Manufacturing, Germfree, IPM Technologies, KeyPlants, ModuleCo Pharma, NNE and Pharmadule. The report includes an easily searchable excel database of all the modular facility and modular clean room manufacturers serving the biotechnology / pharmaceutical industry worldwide.
Several recent developments have taken place in the field of modular construction market. Roots Analysis research team has outlined some of these recent initiatives below. These developments, even if they took place post the release of our market report, substantiate the overall modular construction market trends that have been outlined in our analysis.
The market report presents an in-depth analysis of the various firms / organizations that are engaged in this industry, across different segments, as defined in the table below:
2023 – 2035
Size of Facility
Small, Mid-sized, Large and Very Large
Type of Construction Component
|Process Equipment, Base Building, Mechanical, Electrical and Plumbing System, Process Commodities and Other Construction Components
Type of Facility
|Manufacturing Facilities, Aseptic Filling Facilities, Research and Development Facilities, and Other Facilities
Scale of Operation
Clinical and Commercial
Type of Industry Served
|Pharmaceutical and Biotechnology
|Type of Product
|Cell and Gene Therapies, Vaccines, Biosimilars, Monoclonal Antibodies, Advanced Pharmaceuticals, Sterile Products, Viral Vectors and Other Products
|Type of Facility
|New Facilities, Facility Expansions and Planned Expansions
|Type of Modular Construction
|Permanent and Relocatable
|Type of Material Used
|Steel, Wood and Concrete
|Key Geographical Regions
|North America, Europe, Asia-Pacific, MENA and Rest of the World
|15% Free Customization Option
|PowerPoint Presentation (Complimentary)
|Excel Data Packs (Complimentary)
|Market Landscape Analysis, Modular Cleanroom Manufacturers Analysis, Company Competitiveness Analysis, Partnership and Collaboration Analysis, Case Study on Modular Projects Analysis, Facility Construction Trends Analysis and Market Forecast and Opportunity Analysis
The Modular Construction Market report features an in-depth market analysis, highlighting the capabilities of various stakeholders engaged in this market. Amongst other elements, the research report includes:
The opinions and insights presented in the market report were influenced by discussions held with senior stakeholders in the industry. The market research report features detailed transcripts of interviews held with the following industry stakeholders:
All actual figures have been sourced and analyzed from publicly available information forums and primary research discussions. Financial figures mentioned in this market report are in USD, unless otherwise specified.