A Commitment to Quality for Nearly 200 Years
Located on Motzener Straße in the heart of Berlin-Marienfelde is one of the Klosterfrau Healthcare Group’s most important production sites. On a site spanning approximately 45,000 square meters, the facility produces medications and medical devices that are familiar to many people in their daily lives—from liquid medications and medical lozenges such as neo-angin® to sterile, pre-filled syringes like Instillagel®, which are used in doctors’ offices and hospitals worldwide. Every stage of production meets the strictest GMP standards—a commitment to quality that has defined Klosterfrau’s work for nearly 200 years.
Major Investments in Germany’s Future as a Pharmaceutical Hub
To meet steadily rising demand while ensuring long-term planning certainty, the Klosterfrau Group is investing approximately 60 million euros in new, sustainable production facilities. This multi-year investment program will expand production capacity, strengthen existing jobs, and create additional ones—deliberately located in Berlin and thus in Germany.
“There were two main reasons for our project: first, the need to expand capacity due to rising demand and new products, and second, the consistent integration of our many years of experience into the new factory,” explains Roman Bobryshev, Head of Investments & Site Services at Klosterfrau. As part of the modernization, the company made a conscious decision to choose Berlin as the location: “Germany is extremely important to Klosterfrau—our roots go back 200 years. Staying here in Germany also gives us the necessary influence to ensure our high quality standards, which is only possible with in-house production.”
With this expansion, the company is responding to dynamic market developments, stricter regulatory requirements, and its clear commitment to ensuring high-quality production in Germany over the long term.
New Syringe Production Line: Tradition Meets High Tech
A highlight of the investment project is the modern production line for pre-filled syringes. Klosterfrau Berlin GmbH entrusted io with responsibility for the general planning and construction supervision.
During the planning phase, an overarching needs analysis was conducted, followed by the development of a concept based on those findings. In addition, io ensured compliance with all necessary permits in accordance with legal regulations and standards.
The design and construction planning phase included detailed planning—such as layout, selection of technical components, and planning for integration into the existing infrastructure. Once the planning documentation was finalized, io also handled the bidding process and awarding of contracts for all necessary trades.
During the implementation phase, io provided comprehensive construction supervision and quality control through to the completion of the facility. Subsequent extensive test runs as part of the qualification process ensured functionality, performance, and compliance with the required quality standards.
All process steps—from filling under higher cleanroom conditions, through labeling and blister packaging, to terminal sterilization and automated packaging—are arranged on a single level, thereby enabling a seamless, highly efficient production chain.
The project was implemented despite a challenging global market situation characterized by rising raw material prices and longer delivery times, which required ongoing adjustments. Thanks to the close, collaborative partnership between Klosterfrau and io, the project was nevertheless implemented cost-effectively and completed on schedule.
New Production Line
Capacity & Performance
—Filling volumes: 300–750 kg per batch
—Output: 15,000–150,000 syringes per product
Flexibility
—Capable of
filling 20 different formats—Designed for high-variety production
Operations & Processes
—Year-round three-shift operation on a single floor
—Integrated processes: filling, packaging, autoclaving
—Suitable for highly viscous products.
“I found our collaboration with io on this challenging construction project—in which we were responsible for the building envelope, utility connections, and material flow routes—to be very collaborative. In particular, our joint effort to address the issue of data integrity and the support we received during the successful final acceptance process left me very satisfied,” says Roman Bobryshev.
Sustainability as a Guiding Principle
The investments in Berlin have a clear focus: modern, energy-efficient facilities that conserve resources while expanding capacity. In this way, Klosterfrau not only ensures the production of key brand products but also strengthens long-term employment in the region.
A location steeped in history—and with a bright future
For nearly two centuries, the Klosterfrau Healthcare Group has stood for quality, reliability, and innovation. The Berlin-Marienfelde site demonstrates how this legacy is being carried forward today: through technological excellence, sustainable solutions, and the clear goal of continuing to manufacture strong brands and new products safely and efficiently well into the future.
Klosterfrau is thus making it clear: It is actively helping to shape the future of Germany as a pharmaceutical hub—and Berlin-Marienfelde remains at the heart of this development.
