Merck develops $1B Gardasil production plant in North Carolina

The Durham complex of Merck now operates a new $1 billion, massive 225,000-square-foot bulk substance manufacturing facility to produce bulk ingredients for Gardasil, its major hit HPV vaccine.
Merck constructed a new manufacturing facility on its established 262-acre campus, which has served as headquarters since 2004. The facility produces vaccines, including Gardasil, and prevention medications for chickenpox, measles, and rubella viruses.
Last year, the manufacturing complex manufactured 70 million doses and plans to expand its production this year, as per a Merck spokesperson in an email dialogue. The campus now employs more than 1,000 people.

The manufacturing center gained widespread attention during the coronavirus era because Merck teamed up with Johnson & Johnson to produce substance materials for their unsuccessful COVID-19 vaccine using a Department of Health grant worth $105 million.
The arrival happens at a time when American biopharmaceutical companies are exploring the possibility of expanding their domestic production bases. President Donald Trump announced his plans to enlarge existing trade restrictions on China, Canada, and Mexico, and he threatened additional taxes or tariffs targeting pharmaceutical products from abroad at 25%.
On the streets of Washington two weeks ago, Eli Lilly announced its $27 billion strategy to construct four new U.S.-based manufacturing sites, which would supplement its existing domestic installations.
Since 2018, Merck has dedicated more than $12 billion to building new American facilities for research and manufacturing operations. The company dedicated a planned $8 billion towards building U.S. capital facilities, which will extend until 2028.
Sanat Chattopadhyay from Merck’s manufacturing team declared in their release that the Durham expansion defines an important achievement in their mission to improve U.S. production infrastructure.
Two weeks prior, the state investment board of Delaware had supplied Merck with a $30.2 million grant to develop their Chesnut Run Innovation & Science Park facility outside of Wilmington. The company proceeds with reviewing its selection following the grant allocation that emerged from the local planning and development initiative.

Durham’s new vaccine site contains advanced functionalities that involve data analytics and both generative AI and 3-dimensional printing, according to Merck’s statements. Digital twin technology within the facility uses virtual modeling to evaluate process modifications before their implementation date while providing employee training resources.
The Durham location serves as a TICE BCG production center for bladder cancer medication, which addresses years of supply shortages through capacity expansion facilities. The company stated through email Tuesday that the project should reach completion by the end of this year.