Roche Diagnostics FMB Expansion Project – Branchburg, NJ, USA

Customer and Site Information

The Roche Diagnostics FMB Expansion Project in Branchburg, NJ, is a groundbreaking initiative that exemplifies our shared commitment to sustainability. Designed to be a CO2-free facility, this project is a significant step toward environmentally responsible manufacturing in the pharmaceutical industry.

This marks AME’s first collaboration with Roche Diagnostics, a global leader in healthcare and sustainability. As one of the largest pharmaceutical companies worldwide, Roche’s innovative approach to diagnostics and pharmaceuticals makes this partnership particularly meaningful.

Project Initiation
The project commenced on January 15, 2023, and is expected to complete in early 2025, with the facility fully operational by the start of 2024.

Advanced Integration and Customer Requirements
AME was entrusted with integrating Roche’s legacy Johnson Controls Metasys controllers into a modern Honeywell platform. The project involved:

• Seamlessly connecting the existing CUP with Gas Fired Absorbers to the new Honeywell platform.
• Implementing all-new IP CIPER30 controls.
• Bringing to life a state-of-the-art geothermal/heat pump chiller plant, enabling Roche to meet its CO2-free objectives.

This meticulous integration has modernized the facility and set the stage for future expansions of the Honeywell system within Roche’s operations.

Collaboration and Recognition
The collaboration has been highly successful, with positive feedback from all stakeholders, including the Engineer of record, the commissioning agent, and Roche. The fully operational geothermal/heat pump plant has eliminated the use of gas-fired absorbers, achieving zero emissions for heating in the new buildings. This remarkable achievement was recognized with the AEE Energy Project of the Year Award for 2024 in the Mid-West US.

Project Completion
The final commissioning stages in the warehouse building are set for completion in early 2025. However, the facility already operates efficiently, utilizing advanced Honeywell IP controllers and a Honeywell Supervisor platform implemented by AME.

Ongoing Partnership
Building on the success of the FMB Expansion Project, AME has been invited to bid on Project Pluto, which focuses on upgrading lab spaces within Roche. This opportunity underscores AME and Roche’s strong partnership and mutual commitment to sustainability.

Sustainability at the Core
The Roche Diagnostics FMB Expansion Project is a beacon of sustainability. By integrating geothermal energy and heat pumps for low-temperature heating and cooling, the project has achieved a CO2-free status. This aligns seamlessly with Roche’s long-term sustainability objectives, setting a benchmark for the pharmaceutical industry. The recognition as the AEE Energy Project of the Year further highlights its impact.

Innovative Features
The CENTRAL UTILITY PLANT (CUP) incorporates cutting-edge technologies

• Simultaneous Heating-Cooling Equipment: Generates heating and chilled water concurrently, optimizing energy use.
• Primary-Secondary System: Enhances energy distribution and minimizes waste.
• Ground Loop Heat Exchanger: Acts as both a heat sink and source, boosting efficiency and reducing traditional energy reliance.
• Integration with Existing Cooling Towers: Leverages existing infrastructure to minimize environmental impact.
• Thermal Energy Storage: Features a dual-purpose hot water thermal energy storage/firewater tank to store excess heat, further improving efficiency.

AME’s expertise in controls integration has been pivotal in delivering this innovative and sustainable facility, reinforcing Roche’s leadership in environmentally responsible healthcare solutions.