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Press Clipping / Jun 21, 2021

Hovione meets increased demand during Covid

Irish Examiner, 21 june 2021

Hovione meets increased demand during Covid | Hovione
Hovione staff donating hand sanitiser to a St John’s Ambulance crew. Hovione donated 65MT free of charge to over 150 institutions with the help of charities, local community groups, private nursing homes, local hospitals, sporting clubs, and An Garda Síochána, who dispensed the sanitiser in Templemore Training Centre into smaller bottles for HSE-run nursing homes across the country.

Dr. Paul Downing, general manager of Hovione in Cork, reflects on the values driving the company’s years of global success.

 

When news of a global pandemic broke Hovione, a contract pharmaceutical manufacturing company which helps bring new and off-patent drugs to market, adapted and responded almost immediately. The sudden spike in demand for medicines and for Covid-19 specific treatments required unique mobilisation efforts across the entire Hovione network. “We needed to execute major capital expenditure projects at our sites, maximise operational efficiency, hire additional talent and quickly identify an external partner to expand our overall capacity”, explains Dr Paul Downing, General Manager of Hovione’s manufacturing plant in Cork.

The company, which employs 250 people in Cork and approximately 1,800 more at its other three sites spread over three continents with facilities in Lisbon (Portugal), Macau (China) and New Jersey (USA), has over 60 years experience in the development and compliant manufacture of Active Pharmaceutical Ingredients and Drug Product Intermediates. Hovione began manufacturing hand sanitiser on site in March 2020 for the protection of their team members. Very quickly, they saw public demand grow and in keeping with the company policy of ‘Corporate Citizenship’ this led Hovione Cork to appoint a project team to bring the manufacturing of hand sanitiser to distribution. The hand sanitiser was made readily available for donation to help protect various facilities and institutions across Ireland. The first batch of hand sanitiser was collected for use at St. Stephen’s Hospital in Glanmire in Cork on April 20th. Hovione supplied the sanitiser across Ireland to nursing homes, care facilities, charities and hospitals. The company worked closely with An Garda Siochana to safely distribute hand sanitiser to the HSE — “we organised 65 metric tonne of hand sanitiser to be distributed freely nationally and within the community locally to GAA clubs, churches and other community-based organisations.

Dr. Downing says: “It gave all of us a sense of purpose during a difficult time.” Hovione distributed hand sanitiser free across all of their plants to support the local communities of each country they manufacture in. Dr. Downing explained that when the supply crisis ended in July 2020 the companies who would normally make these sanitising products were back in production so “we stopped and focused on other things”.

He said it was a great privilege to be a part of “this truly global response where we witnessed the pharmaceutical supply chain working together in an unprecedented fashion to treat patients and save lives. I think the global pandemic showed us how important and resilient the life sciences sector is”.

Hovione Cork which took over Pfizer’s former Loughbeg site in Ringakiddy in 2009 plays a significant and strategic role within the Hovione network. The company has seen rapid growth over the last 12 years expanding its production capacity to occupy three separate production buildings at the site.

 

Last September, in the middle of the Covid pandemic, Hovione announced a partnership with US-based Ligand.

This was to support manufacturing of antiviral Veklury for Covid-19 which meant the company needed to significantly ramp up the production output of Captisol leading to the announcement of 48 new jobs for Cork in October 2020.

Dr. Paul Downing explained that Captisol is used in the formulation of Gilead’s Covid-19 treatment Veklury and Hovione is the sole producer of this key enabling excipient. To meet Captisol demand associated with Veklury, Hovione was producing in one month the quantity it normally produced in a year.

Going forward Dr. Downing said Hovione has an ambitious plan to be the Number 1 innovative, integrated pharmaceutical solution provider to the global pharmaceutical industry by 2028.

“Our mission is to passionately turn any challenge into a solution by collaboration with our partners to develop great medicines. That is a company corporate goal so that requires all our facilities to grow and expand so this expansion plan is across the whole Hovione network including Lisbon, New Jersey, Macau and also obviously Cork”.

The company — which was founded by Ivan Villax with his wife Diane Villax in Lisbon, Portugal in 1959 — recently celebrated 62 years in existence.

“In short we give our customers what they cannot find elsewhere”, says Dr Downing who explains that customers come from the sectors of biotechnology, medium, speciality and large pharmaceuticals and generics pharmaceuticals.

Hovione he says has a unique value proposition.

“We have more than 15 years of experience in pharmaceutical spray drying and have produced hundreds of batches for clinical trials and commercial supplies”.

 

Sustainability is hugely important

Hovione was one of the first companies to sign up to Business in the Community Ireland’s new Low Carbon Pledge in 2018 to commit to cutting their carbon footprint, report annually on their progress and develop a credible roadmap towards a net-zero economy.

“Here at Hovione we continue to try and be contemporary, practical and pragmatic. We have a large footprint of a site here so we are investigating if we can install solar power.

“We continue to challenge ourselves in reducing our industrial footprint in terms of energy consumption, water consumption and waste generation so this Ligand product for instance that we worked on is very water-intensive and we did a lot of processing improvements in parallel to this huge ramp up to actually reduce energy, reduce solvent, reduce waste and reduce water. Sustainability is at the forefront of what we do and it starts at the very beginning with our R&D in Portugal.” 

Dr.Downing says he notices when recruiting younger staff, in particular, they are asking ‘what is your sustainability philosophy, what are you doing to reduce your impact’ so you know it has to be real, it can’t just be gestures”. These concerns he says are embedded in Hovione’s core values and purpose — “sustainability is fully integrated into our business strategy”.

Overall Hovione’s steadfast growth is the result of an integrated synergy that allows the company to serve both the global markets and also to respond to specific customer demands when necessary. The company has a solid legacy of Corporate Social Responsibility — in 2018 Hovione became a Certified B Corp — becoming the first facility in Ireland to have received this Certification. The company’s ‘Safety First, Quality Always’ culture is also something staff are very proud of — “we nurture it each day so that we don’t take it for granted”.

In the coming years Dr. Downing said the company will continue to invest in additional capability and hire additional team members, launch and validate more new products.

He points out that the company is an active member of Biopharmachem Ireland, Cork Chamber as well as Business in the Community Ireland. Hovione sponsors and supports local community initiatives as well as establishing crucial links with the academic and training institutions through its support of STEM — initiatives to encourage take-up of subjects such as science, technology, engineering and mathematics — as well as MTU student placements and the Cork Training Centre.

“We are the first Chemical/Pharmaceutical Company integrating this innovative community of companies that use the power of business to solve social and environmental problems. As a Certified B Corporation we want to contribute to redefining success in business meeting the highest standards of social and environmental performance, setting out team members for success and personal satisfaction and aspiring to use the power of markets to solve social and environmental problems.” 

 

Promoting career growth, diversity and inclusion

“We employ 250 people and currently have 18 nationalities onsite”, says Dr. Paul Downing, general manager of Hovione’s manufacturing plant in Cork.

Hovione, he says, is a fast, challenging, and dynamic environment with great opportunities for people with all skill sets at whatever age.

Because the market demands different products, you can work on multiple products and multiple projects at the same time. That gives people a real diversity of experience.

“We like to have a balance between promoting from within and recruiting from outside, so if someone has the desire to move within the organisation, these opportunities arise”.

He says that Hovione is constantly developing its talent pool, and is a big supporter of and encourages apprenticeships for young people where they are given the opportunity to gain some very substantial and important skills, allowing them to take up roles as electricians, fitters, quality-control analysts, instrument technicians, as well as automation technicians.

The apprenticeship programme not only provides participants with the necessary technical and professional skills, but it also provides valuable teamwork experience.

“What we do find is that people can have very strong technical and academic skills, but their team collaboration skills require us to invest in further training.

“These skills would be automatically instilled in participants in the apprenticeships programmes.

“In complex and large organisations like ourselves, the interpersonal skills and an ability to work in small teams is important.” 

Hovione works with Skillsnet and other local academic institutions to help build capabilities that can take advantage of the many career opportunities available.

“We continue to work with Munster Technological University, Cork Education and Training Board, University College Cork.

“We do college site tours and Masters students’ placements. We work with the IDA on the IBEC EOP programme which, before Covid-19, would see graduates spend six months with us and six months with our sister facility in Portugal, mostly working as process engineers or QC analysts.

“We are starting to think of ways to get more diverse employees, so just before the pandemic hit, we partnered with Ireland’s national autism charity AsIAm.

“They are working to create a society in which individuals with autism are empowered to reach their own personal potential and fully participate in society.

“We believe that there may be certain areas within our sector which are very data-intensive like QC, like engineering, which may present opportunities. We were audited to see if we were an autism-friendly workplace.

“We had to change a few things around, including adapting our cafeteria to ensure it had appropriate lighting and noise levels. Some of my team were given training and we hope to do some work with AsIAm post-Covid, and continue to celebrate diversity and inclusivity in the workplace.”

 

Read the article at IrishExaminer.com

 

 

 

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The company is building out more than 200,000 square feet of space in New Jersey. In April, Contract Pharma had the opportunity to tour Hovione’s expanded manufacturing facility in East Windsor, NJ. The company is planning a formal ribbon-cutting this fall; before that, we got an inside look at some new features. Having established United States operations in 2002, Hovione now has more than 200,000 square feet of space in New Jersey. This will be developed into a large, integrated campus in the next five to ten years. Overall, the company’s recent NJ expansion, which began in 2025, has tripled its total spray-drying capacity in the U.S. Future Facility Upgrades A 125,000-square-foot greenfield acquired by Hovione at the East Windsor campus will eventually be a large-scale production site. This includes enhanced quality control and R&D capabilities. Together, all this adds to Hovione’s stable of manufacturing sites, R&D centers, and other offices spread across three continents. Key to the expansion is a targeted reduction of Hovione’s carbon footprint by 40% by the year 2030. Part of this goal is embracing new and/or changing solvent types to help meet sustainability standards. Additionally, the company says automation that has been put in place at its Portugal site will be replicated in NJ. Hovione Aligns NJ Operations At the Drug, Chemical & Associated Technologies Association (DCAT) Week in New York in March, Contract Pharma met with Hovione. There, David Basile, Vice President of Technical Operations—Americas, further illustrated the New Jersey expansion. “Hovione aims to build an equivalent manufacturing network, where clients can go to any site across the globe,” Basile said. “The design of the facility has been well-thought through with material flows [and] gravity-fed processes. 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.” Ultimately, with these moves and a strategic partnership model, Hovione aims to provide customers an opportunity to co-invest and access the company’s proprietary knowledge and assets to accelerate programs and create long-term value. Read the full article at ContractPharma.com    

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The podcast "The Next Discovery" is a six-episode series created by Observador, a leading Portuguese digital newspaper and radio station, in partnership with Hovione.   From hospitals to patients’ homes, discover the solutions that make it possible to administer high-dose biologics with greater comfort, less pain, and more freedom in treatment. What if some of the scientific breakthroughs that could improve the lives of millions of people were happening right now in Portugal? The Next Discovery. Listen to the last episode of the podcast here, featuring João Pires and Joana Cristóvão from Hovione’s Research and Development Center. [English transcription] Nelson Ferreira (NF): Welcome to the sixth and final episode of The Next Discovery, a podcast series in which Hovione opens the doors to its world to share the global impact of innovation developed in Portugal. I’m Nelson Ferreira, and throughout this journey we have explored chemical processes, ultrafine particles, and revolutionary production lines. Today, we look directly at the future of medicine. After exploring the world of small molecules, we are now entering a new therapeutic dimension: biologic medicines. Based on larger and more complex molecules, these treatments are opening new possibilities for addressing a wide range of diseases. To explain how this field is evolving and how science can make these treatments more effective, stable, and accessible to patients, I’m joined by João Pires and Joana Cristóvão from Hovione’s Research and Development Center. NF: Welcome to you both. João, let me start with you. For someone who has never heard this term before, what exactly are biologic medicines, and what sets them apart from small-molecule drugs, which are more closely associated with traditional chemistry? João Pires (JP): If we think about the medicines we find in pharmacies today, most of them are indeed composed of small molecules. These are simpler structures that are still highly effective and that we can design and manufacture through what we call classical chemistry, a field that has developed its knowledge over the last 150 to 200 years. Biologics are completely different. Because of their complexity, larger size, and structure, they differ mainly in their origin. They are produced from living organisms, such as cells, which, under the right conditions, can function as biological factories. Just as in our own bodies, they allow us to produce and extract substances that can have a significant therapeutic effect for certain diseases. In that sense, biologics benefit from millions of years of evolution, something classical chemistry simply does not have. NF: Biology is what carried out that evolution. JP: Exactly. Biology. That’s part of the beauty of it. NF: Nature carried out that entire process for us. NF: Joana, since these medicines are created from living organisms, can we say they are, in a way, more “intelligent” and have greater therapeutic potential? Joana Cristóvão (JC): In some cases, they do have tremendous therapeutic potential. One of the advantages of these molecules is their remarkable specificity. You can think of it as a key fitting into a lock. It has to be the right key. Biologics, because they speak the same biological language as our bodies, have this advantage. However, that does not mean they are better than small molecules. It means that, because they are produced by living microorganisms, they are highly complex and would be very difficult, and in some cases impossible, to produce through traditional chemical synthesis. Their great strength lies in their specificity. Examples of biologics include proteins that facilitate communication within the body and monoclonal antibodies that identify specific targets. These functions are particularly suited to biologics and less common among small molecules. NF: João, as I understand it, this is still an emerging field worldwide. How did Hovione, a company historically linked to chemical synthesis and small-molecule particle engineering, decide to embrace the challenge of biologics? JP: Honestly, it has been a very natural transition. Over the years, Hovione has developed highly specialized expertise in chemistry, particle engineering, and formulation science. When we look at biologics, despite their greater complexity, the underlying challenge is very similar. These medicines still require materials, processes, and controls to ensure they reach patients safely, consistently, and effectively. NF: But is there real potential? JP: Absolutely. Not only is there potential, but there are also significant challenges. This leads to the second point: curiosity. Throughout Hovione’s history, starting with our founder, there has always been a drive to embrace increasingly complex challenges. That curiosity is part of our DNA, particularly within our Innovation and Development Center. It is also one of the most rewarding aspects of working at Hovione: being part of this transition. NF: And it is not that far removed from Hovione’s history either. JP: Exactly. NF: Joana, in which therapeutic areas have biologics already had the greatest impact? Are there diseases where they have clearly transformed patient treatment? JC: There are several areas. NF: So this is no longer science fiction. It already exists in practice. JC: Exactly, and it has existed for quite some time in some fields. In oncology, for example, antibodies are used to target and kill cancer cells with high specificity. Instead of attacking cells broadly, these treatments target the disease’s underlying mechanisms. NF: Which I assume reduces side effects. JC: It does. Cancer is also a very clever disease. It evolves rapidly and often hides from our immune system. There are biologic therapies designed to help our natural defenses do their job by removing the “invisible cloak” that some tumors use to evade detection and progress rapidly. Another classic example is diabetes. Insulin has been the most common treatment for diabetes for decades. Before biotechnology, insulin was extracted from animals, making production limited. With biotechnology, we gained the ability to produce human insulin, known as recombinant insulin, using living microorganisms. This transformation made the treatment available to far more people and has saved countless lives. NF: Two clear examples where biologics are already making a difference. João, these medicines are on the market today, but I imagine developing and stabilizing them in the laboratory presents major technical challenges. What are they? JP: Because these molecules are highly complex and, as Joana described, quite elegant, they are also extremely sensitive, almost like greenhouse flowers. Biological evolution has optimized them to survive under very specific conditions, conditions that often do not exist during manufacturing, transportation, or administration. As a result, they are highly sensitive to heat, air, pressure, and even prolonged contact with one another. When these molecules interact too much, they can lose their structure and unfortunately their therapeutic effect as well. This is where we come in. Clients often approach us with molecules that have tremendous therapeutic potential but are still only proof-of-concept projects. Our role is to take those early experimental results and develop the controls, processes, and formulations needed to scale production to thousands or even millions of doses while maintaining impeccable quality and stability. NF: Joana, how are these medicines administered? Are they different from conventional drugs? Traditionally, many biologics require intravenous administration in a hospital setting. Is that still the case? JC: Traditionally, yes. Most biologics are administered directly into a vein through an infusion, similar to receiving an IV drip. However, the pharmaceutical industry is not only focused on treating diseases. It is also increasingly focused on the patient experience. These treatments require hospital visits and can take time to administer. For chronic illnesses, this process repeats throughout a patient's life. The industry's goal is to develop alternative treatments that are more comfortable and give patients greater independence. NF: So they would no longer need to go to the hospital. JC: Exactly. The ultimate objective is to create injectable solutions that patients can administer themselves. Achieving this requires innovation in technology, formulation development, and medical devices. NF: João, this is where high-concentration formulations come in. What does that mean in practice? Could we eventually administer these medicines ourselves without the help of a nurse? JP: We certainly hope so. The concept of high-concentration formulations is relatively simple: fitting as much medicine as possible into the smallest possible volume. Ideally, that volume is small enough to fit into something like an auto-injector that can be carried in a pocket. NF: A pen-like device. JP: Exactly, a pen. Thanks to newer treatments, particularly in areas such as obesity, these devices have become much more familiar to the public. Technically, it sounds simple: more medicine, less liquid. But as we discussed earlier, these molecules are highly sensitive. As concentration increases and the molecules become more crowded together, challenges emerge. In addition to stability concerns, there is the issue of viscosity. This is easy to visualize: the more concentrated something is, the thicker it becomes. NF: Which makes it harder to inject. JP: Exactly. And greater viscosity generally means greater pain during administration. That directly contradicts the goal of developing treatments that are more convenient and patient-friendly. This is one of the major challenges facing the industry today: finding ways to overcome dose limitations and reduce administration volumes without compromising therapeutic effectiveness, convenience, or patient acceptance. NF: Joana, before we finish, what do scientists feel when they look toward the future and see Hovione’s work helping bring medicine closer to solutions that are increasingly personalized, convenient, patient-centered, and comfortable? JC: I think it is a tremendous responsibility, and that responsibility is also a major source of motivation. Medicine is becoming increasingly personalized and focused on the biological mechanisms that cause disease rather than simply treating symptoms. It is incredibly rewarding to be part of teams contributing to this journey toward a better future, one that places patients at the center. NF: João, is the future biological? JP: Not exclusively, but certainly in part. Biologics allow us to dream bigger. They open the door to better, more personalized, and more effective medicines, creating possibilities that were difficult to imagine until now. NF: João Pires and Joana Cristóvão, thank you for opening the doors to the future of medicine. With this look toward tomorrow, we conclude the first season of The Next Discovery. Over the course of six episodes, we traveled from a basement laboratory in Lisbon in 1959 to global technological leadership that now touches the lives of more than 80 million people every year. These conversations have shown that with curiosity, rigor, and talent, the next great scientific breakthroughs can indeed bear the signature of our country. To listen to all episodes of this series, visit observador.pt or your favorite podcast platforms. Until the next discovery.

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