Strategic Renovation: Updating a QC Lab to Meet Rising API Demands
Ajinomoto Health & Nutrition North America leaders and team members gather to celebrate the grand opening of the company’s newly renovated Quality Control Laboratory in Raleigh, NC. Image: Courtesy of Ajinomoto Health & Nutrition North America
When Ajinomoto Health & Nutrition North America, Inc. (AHN) reopened its Quality Control Laboratory in Raleigh, NC, following a $2.1 million renovation, the project marked more than just an investment in bricks and mortar—it signaled a strategic shift to support the company’s expanding role in the global pharmaceutical supply chain. For organizations facing pressure to modernize aging lab infrastructure while maintaining production continuity, AHN’s approach offers a valuable case study in thoughtful renovation, operational efficiency, and future-proofing.
Rather than building a new facility from the ground up, AHN made the deliberate choice to overhaul its existing lab. According to Jay Dzubak, senior specialist in quality assurance and the internal design lead for the project, the original space had sufficient square footage but was hampered by an inefficient layout and outdated workstations. “The laboratory space was adequate in terms of overall footprint; however, the layout was inefficient, and the workstations were outdated and in need of modernization,” says Dzubak.
This recognition of latent potential in the existing footprint shaped the renovation strategy. With engineering firm DPS providing architectural drawings and Dzubak leading the internal design decisions, the project focused on optimizing workflow while maintaining regulatory compliance—particularly important given the lab’s role in producing Active Pharmaceutical Ingredient (API) amino acids.
A user-driven design process
Early and ongoing engagement with lab staff helped Ajinomoto Health & Nutrition North America create a reconfigured Quality Control Laboratory with clearly defined zones, upgraded infrastructure, and minimal operational downtime during the phased renovation. Image: Courtesy of Ajinomoto Health & Nutrition North America
A key takeaway from AHN’s process is the level of engagement with lab users from the outset. “During the initial phases of the project, we held regular meetings with lab staff to explore layout configurations that would enhance workflow efficiency,” Dzubak explaines. “Although both internal and external design teams influenced many material decisions, we entered the process clearly understanding our desired functional layout. Some user-driven insights also helped shape the final renovation approach.”
These sessions helped surface practical concerns and inefficiencies that might have otherwise been missed, such as poor adjacencies and traffic flow between testing zones. The result was a lab reorganized into clearly defined zones that logically grouped instruments and testing functions—supporting smoother, faster workflows.
While many analytical instruments remained in place, the team used the renovation as an opportunity to selectively upgrade infrastructure such as fume hoods, laminar flow hoods, and ovens. Compatibility and spatial coordination were carefully addressed in layout planning, ensuring that new components integrated seamlessly with retained assets.
Downtime and workflow management
A common challenge during laboratory renovations is managing downtime. Shutting down operations isn’t always an option—especially in regulated environments supplying critical materials. AHN navigated this constraint by phasing the renovation to maintain continuous lab operations. “The renovation was executed in carefully planned phases to ensure the laboratory remained fully operational throughout the process. This required extensive coordination and proactive planning to account for all functional areas, minimize disruption, and maintain uninterrupted production activities,” Dzubak notes. This required detailed scheduling and communication among internal teams, contractors, and vendors to avoid disruption.
The lab retained most of its analytical instrumentation, but as Dzubak explains, “We strategically upgraded select infrastructure components, including fume hoods, laminar flow hoods, and ovens, to enhance performance and align with current operational standards.”
Despite keeping the core equipment, the impact was dramatic. “The space is unrecognizable in basically every aspect except for the instruments and footprints of the lab,” Dzubak says.
Safety, compliance, and scalability
Ajinomoto Health & Nutrition North America's renovated Quality Control Laboratory features enhanced safety, GMP-aligned security, and a scalable layout designed to streamline workflows, support future growth, and improve audit readiness. Image: Courtesy of Ajinomoto Health & Nutrition North America
Beyond aesthetics and workflow improvements, the renovation addressed critical functional requirements. Enhanced access controls and security measures now bring the facility in closer alignment with Good Manufacturing Practice (GMP) standards—key for maintaining integrity in API manufacturing.
Additionally, the redesign emphasized scalability. By preserving open work areas and modular workspace configurations, the new lab allows for future expansion and equipment integration as AHN’s production demands grow. “We enhanced lab safety and security measures to support GMP compliance and reconfigured the layout to consolidate instruments and associated testing functions into logically organized zones. Previously, equipment was placed wherever space allowed, which limited efficiency. The new layout supports streamlined workflows and operational clarity. Additionally, we preserved ample workspace to accommodate future scalability, allowing for potential expansion or integration of new equipment,” says Dzubak.
Measuring success
AHN plans to track the renovation’s success through several lenses: improved workflow speed, enhanced audit-readiness, and better stakeholder engagement. “The redesigned lab layout not only enhances safety and security but also presents a more professional and organized environment, improving our ability to host external stakeholders and conduct customer audits with greater confidence. The streamlined configuration accelerates release timelines by enabling more efficient workflows, while the reserved workspace supports future scalability and equipment expansion,” Dzubak says.
For other organizations exploring lab renovations, AHN’s experience offers several lessons: invest in user feedback, don’t underestimate the potential of your existing footprint, plan for phased execution to maintain operations, and design with future growth in mind. As demand for pharmaceutical-grade ingredients rises, facilities like AHN’s upgraded QC lab will be essential—not just as centers of quality control, but as strategic assets in competitive global markets.
