BioPharmaChem Skillnet Case Study

TU Dublin, in collaboration with BioPharmaChem Skillnet, has co-developed pioneering virtual reality (VR) training programmes tailored for the pharmaceutical and biopharmaceutical sectors. These programmes focused on Aseptic Techniques for Biomanufacturing, Powder Handling, and Health and Safety, representing a major leap forward in workplace training, combining immersive technology with industry-specific expertise. 

The initiative was led by Dr Brian Vaughan, Founder and Director of the Virtual Interaction Research Lab (VIRaL) at TU Dublin. VIRaL is a state-of-the-art research centre specialising in spatial computing and immersive technologies (MR/AR/VR), and operates within the School of Media. The lab is known for its innovative, applied research and close collaboration with industry partners. 

 

Addressing Industry-Specific Training Challenges 

The biopharma sector faces unique constraints in training environments, particularly around the fill-finish line, where a single batch can be worth millions of euros. As BioPharmaChem Skillnet Network Director Susan Costello explains, “Companies can’t afford to train staff in live environments, and traditional methods like shadowing or training during machine downtime are costly and inefficient.” 

Recognising this challenge, BioPharmaChem Skillnet connected with Dr Vaughan, whose previous VR work, including fire safety training for the Mater Private Hospital, demonstrated the potential of immersive learning. This led to the idea of developing a bespoke VR programme for aseptic techniques. 

 

Co-Designing Immersive Learning Experiences 

The development process was deeply collaborative. VIRaL’s pedagogical approach, grounded in situated and kinaesthetic learning, allows trainees to learn by doing within realistic, simulated environments. TU Dublin and BPC Skillnet worked closely with industry trainers to ensure the programme was flexible, relevant, and adaptable to real-world needs. 

Before development began, Vaughan and his team visited a pharmaceutical site in Ringaskiddy, Cork, to demo VR technology to employees from multiple companies. These hands-on sessions helped build familiarity and trust in the technology. VIRaL also ran educational workshops to introduce VR and mixed reality concepts to industry staff. 

Domain expertise from BioPharmaChem Skillnet was essential. “We didn’t know about aseptic techniques,” Vaughan notes. “Working closely with BioPharmaChem Skillnet, they provided the critical knowledge around bacteria, viruses, and fungi that informed the training content.” 

 

Rapid Rollout and Sectoral Impact 

The first programme, Aseptic Techniques for Biomanufacturing was delivered in early 2021. The COVID-19 pandemic, while causing delays, also accelerated adoption by enabling remote training and helping prevent skill atrophy. 

This success led to the development of two additional programmes: 

• Powder Handling in Pharmaceutical Manufacturing: Focused on protecting workers from hazardous substances, this programme addressed training needs in traditional pharma environments. 

• Health and Safety: Delivered in 2025, this programme uses VR to simulate workplace hazards such as slips, falls, and improper lifting techniques. It includes interactive elements like gamified hazard recognition and forklift safety protocols. 

These programmes have provided for greater engagement, flexibility, and effectiveness, and have helped reduce training time, improve retention, and enhance workplace safety. 

 

Recognition and Research Validation 

The collaboration has received widespread recognition. The Health and Safety VR programme was shortlisted for the Excellence in Health and Safety Award at the Life Sciences Industry Awards 2025, highlighting its sectoral impact and innovation. 

Independent research has also validated the effectiveness of the training. Reg Bennett, a life sciences professional, conducted a study comparing traditional training with the VR programme in Aseptic Techniques for Biomanufacturing for his Master’s dissertation. “The difference in feedback was astonishing,” he said. “There was no negative response to VR, and many participants became strong advocates after experiencing it firsthand.” 

 

Driving Innovation and Economic Growth 

By simulating real-world hazards, VR training significantly improves employee preparedness, creating a safer and more resilient work environment. As Susan Costello further explains:

“This initiative addresses a real need for more effective, scalable, and engaging safety training. It supports a safer, more compliant workforce and demonstrates the transformative power of digitalisation in the biopharma sector.” 

Susan Costello, BioPharmaChem Skillnet Network Director

 

Beyond training outcomes, the partnership has contributed to job creation, sectoral growth, and economic sustainability. By embracing immersive technologies, BioPharmaChem Skillnet and TU Dublin are setting new standards for workplace learning and reinforcing Ireland’s position as a global leader in health innovation. By simulating real-world hazards, VR training significantly improves employee preparedness, creating a safer and more resilient work environment. 

 

University Enterprise partnership

Learn more about the BioPharmaChem Skillnet / TU Dublin's ongoing collaborations here.