Press Room

Press Release / Nov 11, 2021

Hovione invests $170 million in new capacity and capabilities

Hovione, the global leader in spray drying and particle engineering, today announced that it is expanding its industrial facilities around the world to support its ambitious growth objectives

Jean-Luc and Guy Villax at CPhI Hovione's booth in Milan | Hovione the global leader in spray drying and particle engineering

Jean-Luc Herbeaux, COO, and Guy Villax, CEO at CPhI Worldwide, in Milan.

 

Milan, 10th November, 2021 – Hovione, the global leader in spray drying and particle engineering, today announced that it is expanding its industrial facilities around the world to support its ambitious growth objectives. The company has been on an expansion track since 2016 in Portugal, Ireland and New Jersey with the aim of continuing to increase its capacity and capabilities to address customer needs.

 

The announcement of a $170 million investment in Hovione units in Portugal, Ireland, and New Jersey, leading to a global capacity increase of approximately 25%, was made at CPhI Worldwide, in Milan, by Guy Villax, CEO, and Jean-Luc Herbeaux, COO. 

 

These investments will be used to support growth in the company´s pharma custom development and manufacturing service business, fueled by strongly growing demand for Hovione´s integrated and differentiated services in drug substance manufacturing, particle engineering and most recently drug product manufacturing. The expansion will go hand-in-hand with a build-up of Hovione´s global team with the creation of more than 300 new jobs globally. This strategy will allow the company to continue to address difficult-to-meet client needs while reinforcing its commitment to the Hovione values and standard of quality.

 

In the USA, Hovione will add a 2900m2 building next to its current facility in East Windsor, New Jersey, laying the foundations for a state-of-the-art Hovione Campus. The upcoming cycle of investment will bring additional commercial spray drying capacity online by 2023. Further investments will follow with the aim to solidify the company´s integrated offer: API - Particle - Drug Product in the region. This expansion will allow Hovione to accompany existing and new customers favoring US-based manufacturing through their development cycles all the way to commercial.

 

The capacity and capabilities of Hovione´s Cork site in the Republic of Ireland will also be upgraded to enable the production of Highly Potent Active Pharmaceutical Ingredients (HPAPI) and to facilitate onboarding of Drug Substance Manufacturing projects of all sizes. The investment will create an ecosystem in which large customer projects with unique technologies can find a home by connecting to the existing infrastructure and equipment. The site will also receive a new commercial size spray dryer to support the growing demand for particle engineering services. 

 

In Portugal, Hovione is ready to start operations of its most recent facility with an increase in chemical synthesis capacity for High Potency Active Pharmaceutical Ingredients (HPAPI). The building is also prepared to receive a new commercial spray dryer to respond to the future needs of the global drug market.

 

“Hovione is in it for life and what better way to manifest this than through expansion of our global capacity and capabilities. Our sustainable organic growth strategy will allow us to keep true to those values that have been guiding us for more than 60 years”, says Guy Villax, Chief Executive Officer.

 

“These investments reinforce our integrated specialized offer globally, providing our clients with a line of sight for their projects. Focus is placed on facilitating and speeding up the drug development cycle and launch, by providing API manufacturing, Particle Engineering and Tableting services in each site. Our strategy continues to be to grow organically via investments in our existing sites, which are designed for purpose. This reduces the complexity associated with the growth journey and allows us to focus our management attention on what counts most, i.e. guaranteeing that our clients go to market with quality, safe and effective medicines for their patients” says Jean-Luc Herbeaux, Hovione’s Chief Operation Officer.

 

About Hovione: Hovione is an international company with over 60 years of experience as a Contract Development and Manufacturing Organization (CDMO) and is currently a fully integrated supplier offering services for drug substance, drug product intermediate and drug product. With four FDA inspected sites in the USA, China, Ireland and Portugal and development laboratories in Lisbon, Portugal and New Jersey, USA, the company provides branded pharmaceutical customers services for the development and compliant manufacture of innovative drugs including highly potent compounds. For generic pharmaceutical customers the company offers niche API products. In the inhalation area, Hovione is the only independent company offering a complete range of services. Hovione is a company with a culture based on innovation, quality and delivery. Hovione is a member of Rx-360, EFCG and participates actively in industry quality improvement initiatives to lead new global industry standards. 

 

 

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The CDMO is preparing for its New Jersey facility to become fully operational this year. Hovione’s multimillion-dollar investment in expanding its East Windsor, NJ manufacturing site is quickly coming to fruition. Contract Pharma will be visiting the site later in April 2026 to provide a unique overview of what’s new. As a preview, the Contract Pharma team met with Hovione at the Drug, Chemical & Associated Technologies Association (DCAT) Week. David Basile, Vice President of Technical Operations—Americas, spoke at the opening Member Company Announcement Forum on March 23, 2026. In this interview, Basile expands on his remarks at the Announcement Forum. As he explains, Hovione is concentrating not only on New Jersey, but also on facilities in Ireland and Portugal. Contract Pharma: Good manufacturing practice (GMP) operations will soon be fully operational at the New Jersey facility. How has Hovione progressed through this process since the initial investment cycle was announced last fall—or even prior? David Basile: It’s been a really great journey and evolution over the last two to three years, conceiving the plan to grow our U.S. footprint. It was one of the reasons I came aboard with Hovione, to grow that footprint and build our commercial manufacturing prowess in the States. In New Jersey, we had originated [the site] as a tech transfer center. [But] we wanted to grow the organization to be more equivalent with our Portugal and Ireland sites, to do more large-scale manufacturing. So, this is part of that journey. And that’s not just bricks-and-mortar and machinery. It’s been people, talent, partnerships with clients, supporting functions such as QC [quality control] and analytical development. We’re growing our R&D teams as well. It’s a comprehensive approach to systems, people, and processes. CP: At the Member Company Announcement Forum, you ran through some of the major technical specifications of the NJ expansion. Can you talk about a few of the highlights and their capabilities? Basile: This year we’ll be starting up two PSD-3 scale spray dryers. This is a useful scale of machinery for our clients. It plays nicely between the PSD-2 and PSD-4 scales that we have elsewhere in the network. I’d say it’s medium-to-large scale capacity; we could do 30 metric tons annually out of this type of a unit. Product to product, that differs, but we do have products that put that kind of volume out in a PSD-3, so it’s not small-scale. Customers want to hear this because [they want to gain] efficiency with their batch size, and turnaround time. And when we campaign, we can really see significant throughput with this line up of new machinery and assets. The first machine that we will start up is a Hastelloy unit, which is unique. We took a pause [in the construction timeline] to make that upgrade, as we had a client that needed this configuration. There are additional clients that are interested in it too, because you can do acidic solutions and more aggressive kinds of formulations as well as solvent-based formulations. So that’s a unique element of that first machine. The second machine is being qualified later this year. Kind of a twin, but this one is standard 316 stainless steel.  CP: When a company brings a new or expanded facility online, new personnel often accompanies the new tech. What is the workforce addition that you expect, and what are the challenges of retaining top talent? Basile: In preparation for commissioning and startup of this new equipment, we’ve already ramped our headcount up, to be ready for GMP launch. We’ve added roughly 20 employees in preparation for this first machine to go [live]. Over the next 18-plus months, we could see something on a similar scale, getting us up to that 40–50 headcount range for that facility once it’s fully operational—and more later on in 2028, when we bring in the CDC [continuous direct compression] Flex unit. That’s what’s really going to be transformative about this new facility: that integrated offering coming to life. CP: Even if the NJ facility is top of mind right now, let’s also touch on some of your plans in Europe. What is your vision for expanding in Europe in the next two to three years? Basile: Ideally, Hovione’s aim is to build an equivalent manufacturing network, where clients can go to any site across the globe and get a similar breadth and scale of offering. We’re doing that now in Ireland, expanding our PSD-4 scale spray drying. One unit was recently installed. Late last year, it went live. Then there’s at least one other new PSD-4 in motion, which is really exciting, because [spray dryers] at this site were historically [exclusive to] larger chemistry manufacturing for API [active pharmaceutical ingredient] synthesis. So now, they’re further building their muscle with additional large scale spray drying capacity. On the Portugal side, there’s a lot of great things going on. Our Tejo campus, in Seixal, Portugal, is a massive, 4.5-million-square-foot plot of land, and there’s a new, modular facility going up there. It’s incredibly exciting. The design of the facility has been well-thought through with material flows [and] gravity-fed processes. Here, we minimize handling and [maximize] speed of processing. It’s scalable. We call each one of these building segments a finger. You can copy and paste these fingers, and they are built to house both spray drying and drug product assets within each unit. So, why is that relevant? Because we can easily scale the number of fingers. When customers say, “we need more capacity,” we have the design on the table ready to go. We know how to execute, we know how to build and implement our technology platforms in a short timeframe. Deployment timeframes are truly becoming more and more relevant to our clients. CP: From last year’s DCAT Week to this year’s, what conversations are you having with industry colleagues about ever-changing geopolitics? Basile: We’re seeing that local, regional manufacturing capacity is vital. The concept of U.S. for U.S. and China for China seems to be a common theme that our clients are talking about. We happen to have an edge, as we [have already] started our journey of expanding our domestic U.S. capacity. So I think that’s a crucial piece to the puzzle, having dual-sided Atlantic manufacturing operations. The traditional global supply chain model is being challenged. Having soup-to-nuts sites that are fully autonomous in development, scale-up, tech transfer, all the way to commercial scale operation, is vital to Hovione, and how we’re protecting our supply chain. [Concerning] starting raw materials and Tier 2 suppliers, our procurement teams are out in the market making sure that there’s no single point of failure for critical materials [like] polymers and solvents that we utilize. We’re managing and mitigating risk by looking at those secondary suppliers across different geographies. CP: Encapsulating your planned expansions on both sides of the Atlantic, how would you sum up the value to the customer? Basile: It’s about speed-to-market. It’s one partner from early-phase development, clinical scale, all the way through commercial. They gain comfort, trust, and not just capacity and equipment time; it’s also about competency and depth of scientific expertise. We’re not just a traditional CDMO. There’s unique expertise in particle science and spray dried dispersions that we offer our clients that they don’t have. [With] traditional CDMOs, customers typically pay for time in [a particular] unit, for example, they’d say: “I need a machine, and I need [it for] three weeks.” Hovione is truly a partner to our clients. They’re leveraging our platforms, our know-how in spray drying, and our know-how in equipment design. Read the article at ContractPharma.com  

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With key expansions coming to fruition on either side of the pond, specialist CDMO Hovione is making sure that drugmakers can access its particle engineering expertise across multiple geographies.  That flexibility will be key for the Portugal-based company in the coming years as the pharmaceutical industry continues to embrace more regional supply chains. In a recent interview, Hovione's David Basile, VP of technical operations for the Americas, discussed this trend and the manufacturer's expansion project, which is set to come online in New Jersey next month.  In the coming weeks, Hovione plans to debut a new spray drying expansion at its campus in East Windsor, New Jersey. The company has invested $100 million to expand its campus, including new construction and the acquisition of an additional facility and greenfield land.  Specifically, one of two pharmaceutical spray drying-3 units, or PSD-3 units, will come online in the coming weeks to tackle amorphous active pharmaceutical ingredients (APIs) and amorphous solid dispersions, according to the company. With some 80% of new small molecules in development insoluble in water, Hovione’s particle engineering and amorphous solid dispersion platform helps medicine developers improve the solubility, bioavailability, and, in some cases, the stability of their drug candidates, Basile said.  The company boasts spray dryers from the lab scale to PSD3 at its original facility in East Windsor, in addition to the pair of large-scale machines about to be activated at the campus' new facility.  “We’re going for a single, unified site with capabilities across the campus to do drug substance through finished drug product under one governance and quality system,” - Basile told Fierce.   Read the full article at FiercePharma.com

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Twenty companies presented at the annual kickoff to DCAT Week. The Drug, Chemical & Associated Technologies Association (DCAT) opened DCAT Week 2026 with its Member Company Announcement Forum. The kickoff to the annual event in New York City, underway from March 23–26, 2026, showcased 20 companies. These were selected based on their announcements’ “news priority, criticality, and interest” to DCAT member companies. The following is a summary of highlights from the presentations, supplemented by additional information provided by some of the companies. (...) Hovione Hovione’s Vice President of Technical Operations for the Americas, David Basile, delivered the company’s Member Company Announcement Forum presentation. Basile will be speaking exclusively with Contract Pharma during DCAT Week, so check back for more on Hovione’s latest.   Read the full article at ContractPharma.com    

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