Stephen M. Hall

About Us

Stephen Hall brings proven and trusted expertise to drive engineered capital projects for pharmaceutical manufacturers. He leverages his technical know-how with his management background and broad regulatory compliance experience to benefit the engineers, scientists, and operators who are tasked with executing the design, construction, start-up and qualification of new or renovated manufacturing facilities. His book, Rules of Thumb for Chemical Engineers, gives practical advice, information and mathematical formulas that are used by process and project engineers throughout industry (Butterworth-Heinemann, 2012).

His projects portfolio includes large grass-roots facilities, such as MannKind’s $200 million inhaled insulin manufacturing facility which won two categories in the 2010 Facility of the Year Awards program sponsored by ISPE, and Bristol-Myers Squibb’s $700 million biologics facility in Devens, MA. He’s been working in the industry since the 1970s when he did the process design for Merck’s first Heptavax vaccine facility (for Hepatitis C) in North Wales and for SmithKline’s active pharmaceutical ingredient synthesis plant in Upper Merion, PA. Steve spent two years in Germany with his family during the formative stages of the design firm, Life Sciences – Meissner+Wurst (LSMW). He has provided compliance inspections for plants throughout the U.S., in Puerto Rico and in South Korea.

He is a passionate advocate of using spreadsheet tools for problem-solving, and he is well qualified to design, develop, and support his software products. As an early adopter of computer technology (he was programming his Apple ][ in assembly language in 1980), he has a successful track record in software design. Steve often develops custom spreadsheets as part of his consultancy, answering questions concerning topics such as fluid flow, heat transfer, and product separation. His spreadsheet work includes plant-wide modeling that simulates unit operations and provides insights into plant capacity, material usage, and operating efficiencies.

Steve earned his B.S., Chemical Engineering, from the University of Pennsylvania and his MBA from Drexel University. He authored numerous articles for Pharmaceutical Engineering, Chemical Engineering, Chemical Engineering Progress and others, and presented at various professional meetings. He is based in Philadelphia, doing business as S. M. Hall Consulting, LLC.


Customers work in every corner of the world and include individuals, students, small businesses, engineering consultants, vessel fabricators, contractors, government agencies, and corporate giants. Industry segments range from multi-national petroleum refining to regional irrigation system contracting.

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