Highlights include expansion of biotech operations in Philadelphia, acquisition of a new pharma-device facility near Dublin, Ireland, and a new Center of Excellence for advanced drug delivery and drug-device combination product assembly in Rockford, Illinois.
Philadelphia, PA – PCI Pharma Services (“PCI”), a leading global contract development and manufacturing organization (CDMO) specializing in complex biopharma therapies, has announced a monumental investment exceeding $365 million. This initiative focuses on enhancing infrastructure to support the clinical and commercial-scale final assembly and packaging of drug-device combination products, emphasizing advanced drug delivery systems, particularly injectable formats. Spanning both Europe and North America, the investment is rooted in recent business growth and designed to meet future demand through strategic facility expansion.
Watch this video for highlights of the investment.
PCI’s investment strategy builds on more than 20 years of expertise in biologics and its industry-leading position in advanced drug delivery solutions. Central to this reputation is the Biotech Center of Excellence in Philadelphia, which specializes in prefilled syringes, vial labeling and cartoning, syringe assembly and labeling, and autoinjector assembly. Significant recent investments in cutting-edge automated drug delivery technologies at this location underscore PCI’s commitment to remaining at the forefront of innovation in the CDMO industry. The center’s capabilities enable seamless handling of complex biologics, ensuring both precision and efficiency.
Together, the planned projects bolster PCI’s ability to support the entire lifecycle of drug-device combination products, from sterile drug product development through clinical trials, product launch, and full commercialization. This integrated approach demonstrates PCI’s ability to act as a single-source solution for its clients, streamlining workflows and minimizing potential bottlenecks.
Expansion in the US: A New Center of Excellence in Rockford, Illinois
In the US, PCI is embarking on a 545,000-square-foot expansion at its Rockford, Illinois, campus. This ambitious project is dedicated to advanced drug delivery and drug-device combination product assembly and packaging, positioning the site as a premier hub for pharmaceutical innovation.
The phased expansion includes a 475,000-square-foot facility featuring 345,000 square feet for advanced injectable packaging operations, and an additional 130,000 square feet of warehousing to support products at every stage of development. The facility will host over 20 customizable customer suites and scalable technologies for clinical and commercial-scale operations, encompassing vials, prefilled syringes, autoinjectors, and pen-cartridge systems. Advanced technologies, including top-open cartoning systems and functional product testing to ISO standards, are integral to the facility’s design. These features ensure that PCI’s clients can rely on robust quality control and compliance throughout the production process.
Additionally, a separate 70,000-square-foot facility focused on advanced drug delivery and patient-centric combination product assembly and packaging is planned. This facility will cater to a variety of packaging technologies for injectables, including vials, prefilled syringes, autoinjectors, and on-body injectors. Operations at the first phase of the plant are scheduled to begin in Q3 2025. PCI’s ability to cater to diverse client requirements reflects its dedication to providing tailored solutions that align with the unique needs of each project.
PCI’s investment positions the company as one of the first CDMOs capable of managing the entire lifecycle of advanced drug delivery and combination products under a single roof. Supported by comprehensive cold chain storage solutions, PCI aims to streamline the journey from clinical development to commercialization. The incorporation of end-to-end services ensures that even the most complex therapies are handled with precision and care, reinforcing PCI’s reputation as an industry leader.
Enhanced Operations in Europe: Expanding Presence in Ireland
PCI is also amplifying its European presence through two significant developments in Ireland. The company has acquired a purpose-built pharmaceutical packaging and device assembly facility in Dundalk, designed to accommodate large-scale temperature-controlled storage and packaging operations. Having achieved HPRA approval, the Dundalk facility is now operational and will handle commercial-scale packaging for both injectable and oral solid dose (OSD) drug products. This acquisition reflects PCI’s ongoing commitment to addressing growing demand for these services across the European market.
Further bolstering its Irish operations, PCI is constructing a new packaging and device assembly facility at its CityNorth Dublin campus. Scheduled for completion in Q3 2025, the facility will expand PCI’s capacity for the final assembly, labeling, and packaging of injectable drug products such as vials, prefilled syringes, and autoinjectors. It will also feature cold chain packaging and temperature-controlled storage capabilities tailored to injectable and biologic products. By incorporating state-of-the-art technology and leveraging its expertise, PCI ensures that these facilities can deliver high-quality, patient-centric solutions to its clients.
Both new Irish facilities will leverage PCI’s multidisciplinary expertise in operations, quality assurance, engineering, and project management. Cutting-edge equipment and adjacent services, such as in-house packaging design and analytical laboratories, will enable PCI to provide patient-centric packaging solutions while ensuring a seamless commercial launch process. These facilities are also designed to adapt to evolving market needs, making them a vital part of PCI’s global strategy.
To further support these operations, PCI has recently opened a large-scale warehouse in Dublin equipped with cold chain storage capabilities, following HPRA approval. This additional facility reinforces PCI’s ability to meet growing customer demand while enhancing its commercial packaging capabilities for EU markets. The inclusion of cold chain logistics ensures that sensitive products are handled under optimal conditions, safeguarding their integrity throughout the supply chain.
CEO Perspective
“This substantial, multi-continent investment places PCI Pharma Services at the forefront of the global advanced drug delivery solutions and drug-device combination product assembly landscape,” said Salim Haffar, CEO of PCI Pharma Services. “The new and expanded facilities reflect our commitment to evolving market and customer needs for clinical-to-commercial drug-device final assembly and packaging. It also underscores our purpose of enabling life-changing therapies and improving patient convenience.”
About PCI Pharma Services
PCI Pharma Services is a globally recognized CDMO offering integrated end-to-end drug development, manufacturing, and packaging services that accelerate speed-to-market and maximize commercial success. With over five decades of industry experience, PCI has launched more than 90 products annually and operates across 30 GMP facilities in seven countries, including Australia, Canada, the U.S., Ireland, Wales, Germany, and Spain. The company’s 7,000 employees are dedicated to delivering life-changing therapies to patients worldwide. This commitment to excellence is reflected in the company’s ongoing investments in infrastructure, technology, and talent.
By leveraging advanced technology and consistent investment, PCI meets global drug development needs throughout the product lifecycle, from manufacturing and clinical trial supply to commercialization. Acting as a collaborative partner and extension of its clients’ businesses, PCI is committed to improving patient outcomes on a global scale. For more information, visit pci.com.
PCI’s emphasis on innovation, coupled with its ability to adapt to changing market dynamics, ensures that it remains a trusted partner for biopharma companies navigating the complexities of drug development and delivery. Through its expansive network and expertise, PCI continues to set new benchmarks for excellence in the CDMO sector.
Join or login to leave a comment
JOIN LOGIN