The Formulation, Filling, Inspection, and Packaging (FFIP) project involves the renovation of a 1955 facility at the Sanofi Toronto Site, transforming it into a 3,000 m² (32,800 SF) Formulation and Filling Suite for vaccine production, research, and pandemic readiness. Initially planned to be the first Carbon Neutral project at the site, the facility incorporates energy-efficient systems such as load reduction, energy recovery, low-temperature heating, and low-GWP refrigerants. While delays have postponed its Carbon Neutral status, the facility is designed for future adaptation. Renovated spaces will feature Grade C and D cleanrooms and walk-in refrigeration for material storage.
The Inspection and Packaging renovation, spanning 1,500 m² (20,000 SF) in another building, addresses HVAC obsolescence and deferred maintenance, using low-temperature heating water. The project will support up to 60 million units per year by 2027. The former virology spaces in B53 are being upgraded for aseptic formulation and filling, with Grade C formulation suites for batch sizes up to 1,000L. The facility will use single-use technology (SUT) for flexibility and reduced cleaning. The filling line will handle RTU nested vials and syringes, with a controlled unloading area.
A dedicated washing and sterilizing area will have a Grade D ‘dirty’ side and Grade C ‘clean’ assembly room. Backup stainless steel tanks will supplement existing sterilization operations. Walk-in cold rooms will store raw materials, formulated products, and final filled vials, with double-height racking for efficient storage.