Global Bio 'Super-Gap' Led by Samba Plant 4... Employees' Sweat Reflected Everywhere

Patent Technology Developed In-House, Core Cleanroom Facilities Applied
'Protective Enclosure' Eliminating Network Signal Interference
Introduction of HEPA Filter Box Improving Safety and More
Voluntary Innovation Efforts by Employees Achieve 'Super-Gap'

Samsung Electronics Vice Chairman Lee Jae-yong visited Samsung Biologics Songdo Campus in Yeonsu-gu, Incheon on the 11th of this month to inspect the production facilities of Samsung Biologics Plant 4.
[Photo by Samsung Electronics]

[Asia Economy Reporter Lee Gwan-joo] Samsung Biologics' Plant 4, which began partial operation this month and completed Samsung's global bio 'super-gap,' is attracting attention as patents developed directly by employees have been applied throughout the facility. The technologies applied to the cleanrooms, the core of the facility, are expected to enable safer and more comfortable production. It is also highly regarded for being an innovation led directly by employees.

Sweat and Effort of Employees Infused into the ‘Cleanroom’

All cleanrooms in Samsung Biologics Plant 4 are equipped with ‘Wireless Device Protection Enclosures.’ A cleanroom in a biopharmaceutical production facility refers to a room that disperses airborne particles and minimizes dust generation and inflow while controlling temperature, humidity, and pressure. Generally, wireless network equipment inside cleanrooms is installed above ceiling panels because it can malfunction due to chemicals used during cleaning inside the cleanroom. However, this causes network signals to be weakened by interference from the panels, exposing the process to risks of disruption. Especially since the digitization of large-scale data generated during production and workers’ standard operating procedures are all network-based, and with the increase in remote inspections by regulatory agencies and clients after COVID-19, the importance of a stable network environment has grown.

The wireless device protection enclosure developed directly by employees works on the principle of placing wireless network equipment inside a special case installed in holes in the ceiling panels to eliminate signal interference. Compared to existing technology, this reduces signal attenuation by about 75%, and only 25% of the equipment quantity previously required needs to be installed to achieve a smooth network environment. Another advantage is that maintenance and repairs can be performed without entering the cleanroom even if wireless network equipment malfunctions.

3D design of the enclosure for wireless device protection (above) and comparison of wireless network equipment installation structures. [Provided by Samsung Biologics]

Along with this, a HEPA filter box technology that improves safety, efficiency, and economy has also been introduced in Plant 4. Typically, HEPA filters are used to supply air free of fine particles to maintain a comfortable environment inside cleanrooms. These filters are inspected every 6 to 12 months and replaced every 3 to 6 years. The problem is that the work takes a long time, and if there is leakage at the joints, rework is required, causing frequent delays. Also, replacing HEPA filters attached to the ceiling involves using ladders or lifts, posing risks to workers.

Samsung Biologics employees developed a hinge-utilized HEPA filter box through internal research to overcome these issues. It can be replaced without separate removal, drastically reducing work time, and uses detachable bolts to reduce the risk of falling. Additionally, the spray nozzle for reagents used in filter testing was changed to a one-touch type and relocated to reduce the risk of falling accidents while extending filter life. This technology has been applied not only to Plant 4 but also to existing plants.

Employee Incentives for Patent Applications... ‘Super-gap’ Achieved Through Innovation

The background of the ‘innovation’ infused into Samsung Biologics Plant 4 lies in the employees’ efforts to create a better environment. Samsung Biologics actively supports the process where employees voluntarily propose ideas for safety and work efficiency, realize them as technologies, and apply for patents. During the idea testing process, related team members collaborate, and the in-house compliance management team supports patent applications through technology analysis and evaluation. Based on this support, employees actively engage in technology development through open technical exchanges, and the company provides various incentives to employees who file patents, creating a virtuous cycle. A Samsung Biologics official said, “The company’s most important competitive advantage is excellent human resources,” and explained, “Patent applications for dozens of technologies developed by employees are currently underway.”

At the '2022 Samba Festa' held on the 17th of this month, John Lim, CEO of Samsung Biologics, and new employees are cheering. Approximately 1,000 new hires from last year, the largest number since the company's establishment, attended this event. Samsung Biologics planned this event as a "communication space to enjoy together" to celebrate the first anniversary of these new employees, who make up about one-fifth of the total workforce, focusing on sharing a sense of professionalism.
[Photo by Samsung Biologics]

Meanwhile, Plant 4, which began partial operation on the 1st of this month, will have an annual biopharmaceutical production capacity of 240,000 liters once fully operational next year. This is the largest scale for a single plant worldwide. Samsung Biologics plans to further solidify its world No. 1 title in contract manufacturing organization (CMO) production capacity through Plant 4. Previously, combining Plants 1 (30,000 liters), 2 (154,000 liters), and 3 (180,000 liters), the total production capacity was 364,000 liters, maintaining the No. 1 position. Once Plant 4 is fully operational next year, the total production capacity will reach 600,000 liters. This accounts for about 30% of global CMO production volume and is expected to complete the ‘super-gap’ in the bio market.

This content was produced with the assistance of AI translation services.