CSL Behring's state-of-the-art plasma fractionation facility in Broadmeadows, Victoria, Australia, has been awarded the prestigious 2025 Facility of the Year in the Pharma 4.0 category by the International Society for Pharmaceutical Engineering (ISPE). The recognition highlights the facility's groundbreaking implementation of robotics and automation technologies in pharmaceutical manufacturing.
World's Largest Plasma Processing Operation
The $900 million facility, known as Facility F, stands as the largest plasma fractionation facility of its kind globally. Since opening in 2022 after four years of construction under Project Aurora, the facility has dramatically expanded CSL Behring's processing capabilities, increasing local capacity ninefold to handle over 10 million liters of plasma annually.
"Projects like our Broadmeadows Plasma Fractionation Facility enable us to meet patients' needs with greater flexibility and efficiency," said Laura O'Brien, head of Global Manufacturing at CSL Behring. "This initiative not only enhances our plasma processing capabilities but also sets a new standard for future projects across our global manufacturing network."
Advanced Manufacturing Technologies
The facility's award-winning design incorporates cutting-edge Pharma 4.0 technologies, including a digital twin virtual model of the plant alongside comprehensive robotics and automation systems. ISPE specifically recognized the facility's "full-scale application and integration of robotics and automation technologies" that demonstrate cultural and operational transformation toward Industry 4.0 principles.
The automation extends throughout the manufacturing process, featuring robotic systems that continuously remove frozen plasma from individual donor bottles and bags, then feed empty containers directly to automated shredders. This eliminates manual waste handling, enhances operator safety, and minimizes overall waste volume.
Advanced filtration technology emphasizes sustainability through reusable filter membranes, while robotic cleaning systems ensure repeatable, compliant processes. The facility also features a fully automated warehouse with robotic vehicles that streamline operations.
Critical Therapeutic Impact
The facility processes plasma from Australia, New Zealand, Taiwan, Hong Kong, and Malaysia, as well as commercially sourced plasma through CSL Plasma. The complex fractionation process separates plasma into essential therapeutic components, including albumin, immunoglobulin, and other proteins used to create life-saving medicines.
These plasma-derived therapies treat patients with immunodeficiencies, neurological disorders, shock, and burns. The products are also essential in operating rooms worldwide for transplant patients, surgical patients, and cancer patients, addressing growing global demand for these specialized treatments.
Manufacturing Excellence and Future Impact
Andrew Hodder, Manufacturing and Site Head at CSL Behring Broadmeadows, emphasized the facility's significance for Australian biopharmaceutical manufacturing. "Our modular design approach, advanced automation, and digital twin technology, combined with our commitment to environmental sustainability, have transformed our operations and expanded patient access to lifesaving plasma therapies globally," he said.
The facility employs 1,200 people across manufacturing operations, engineering, quality control, and research and development. Its modular design supports future upgrades and sustainability efforts, including energy-saving systems that align with environmental goals while maintaining operational excellence.
ISPE created the Pharma 4.0 category to recognize facilities that embody technological innovation while demonstrating the ability to transform culture, processes, and workforce orientation toward advanced manufacturing principles. The award underscores CSL Behring's commitment to innovation and transformation in pharmaceutical manufacturing, positioning the company to strengthen both local and global supply chains for critical plasma-derived therapies.
