GSK’s objective 

To expand the blow fill seal vaccine capabilities at its Boronia site through implementation of innovative technology. 


GlaxoSmithKline (GSK) is one of the world’s largest Pharmaceutical and vaccines company. Their goal is to be one of the world’s most innovative and best performing healthcare companies.  

This project was driven to expand the blow fill seal (BFS) vaccines capabilities at their Boronia site with novel technology. The scope included all building and engineering works associated with expanding the existing Block 7 through development of a building.This included installation of clean rooms, as well as all associated support and ancillary spaces including a new plant platform.


Johnstaff’s role

GSK engaged Johnstaff to provide construction management services for the expansion of a pilot facility to test new manufacturing BFS capabilities.

Our team was initially engaged during the early design phase to provide budgeting and programming assistance which also enabled Johnstaff to work with GSK to develop a multi staged building approach.

Johnstaff’s Construction Services included supervising trade, process and specialist equipment installation contractors and managing and coordinating facility commissioning and validation.

GSK BFS Development Facility

Addressing the issues

Johnstaff worked closely with GSK during the early design phase to ensure construction was feasible within the constraints of their business case and existing conditions. This included multiple staging and cost options. 

Limitations of the existing site infrastructure required Johnstaff and our specialist mechanical contractor to identify efficient equipment strategies to mitigate significant site service upgrades. 

map of the project location


  • BFS manufacturing capabilities

  • Construction works completed within a live environment

  • Multiple build, staging and cost options were developed to meet the constraints of the business case and existing conditions

  • Increased manufacturing and packing lines were delivered