06/08/2026
MilliporeSigma’s Project Opal facility in Sheboygan Falls, Wisconsin, is a growing hub for diagnostic and life science manufacturing. The campus includes more than 14 buildings and 600 employees, with Project Opal producing materials used in over one billion rapid diagnostic tests annually, including pregnancy, influenza, malaria, HIV, COVID-19, and food safety tests.
Hooper’s Mechanical Division played a key role in delivering this complex project, providing HVAC, plumbing, process piping, and custom metal fabrication expertise.
The Plumbing team installed a critical underground fire containment system to protect people and the environment. The system includes large-diameter PVC piping, 24 trench drains, and a 26,000-gallon exterior containment tank that captures runoff in the event of a fire. Much of the piping was prefabricated at Hooper’s Fabrication Facility, improving efficiency and enabling installation in subfreezing conditions to maintain schedule.
Crews also installed more than 3,000 feet of electrically fused polypropylene dual-containment piping for the underground process waste system, ensuring safe handling of hazardous materials. Hooper’s Custom Metals group fabricated ten double-bowl, ventilated stainless-steel sinks for laboratory spaces to safely manage hazardous solvents.
On the HVAC side, the team completed one of the largest stainless steel ductwork efforts in recent company history, supporting research exhaust systems with more than 8,000 fabrication shop hours. All ductwork was butt welded and back purged to ensure clean, high-integrity welds critical for this high-tech environment.
Energy efficiency was central to the design. An energy recovery system captures and reuses heat, while a geo-source heat pump provides about half of the building’s heating and cooling needs. These systems work alongside the boiler plant, chilled water plant, and a snowmelt system using over 20,000 gallons of glycol.
This project highlights Hooper’s skilled workforce and collaborative approach in delivering high-performance infrastructure.
