Press Room

Press Release / Sep 16, 2026

Hovione Opens New Facility at New Jersey Campus, Doubling U.S. Spray Drying Capacity

The new facility doubles the company's U.S. spray drying capacity and further reinforces Hovione´s global leadership in this technology platform.

Hovione_89TR_Inauguration_aereal view building | Hovione
  • New 31,000-square-foot facility adds two GMP-ready, commercial-scale PSD-3 spray dryers to Hovione's U.S. operations
  • Expansion strengthens an integrated U.S. pathway from formulation screening to commercial manufacturing of spray dried amorphous solid dispersions under one quality system
  • Milestone completes a $100 million investment cycle in New Jersey and supports Hovione’s long-term vision for a next-generation pharmaceutical development and manufacturing hub

EAST WINDSOR, N.J., Sept. 16, 2026 — Hovione, a globally-integrated pharmaceutical Contract Development and Manufacturing Organization (CDMO), has opened 89 Twin Rivers, a new 31,000-square-foot facility at its East Windsor, N.J. campus that doubles the company's U.S. spray drying capacity and further reinforces Hovione´s global leadership in this technology platform. 

The facility adds two GMP-ready, commercial-scale PSD-3 spray dryers, expanding Hovione´s manufacturing capacity central to its integrated development and manufacturing platform spanning drug substance, spray drying and drug product manufacturing. Operating under the campus´s existing FDA registration and harmonized quality system, the expanded platform enables customers to reduce technology transfer, facilitate scale-up and provide greater manufacturing continuity.

Approximately 70% of small-molecule drug candidates exhibit poor aqueous solubility, limiting bioavailability and slowing development. Hovione addresses this persistent formulation challenge by turning poorly soluble drug ingredients into more bioavailable forms using amorphous solid dispersions through its specialized spray drying platform. The company also draws upon more than 25 years of specialized manufacturing expertise in spray drying featuring formulation science, predictive and model-based development tools, scale-up expertise and drug product manufacturing to help customers address this challenge.

The opening of the 89 Twin Rivers facility completes Hovione's current $100 million U.S. investment cycle and represents the first major milestone in the next phase of evolution of its integrated East Windsor, N.J., campus. Over the coming decade, Hovione’s vision is to continue growing its U.S. operations, further strengthening the site as a next-generation pharmaceutical development and manufacturing hub. The new facility will employ approximately 80 people.

“Opening 89 Twin Rivers is more than a capacity expansion. It marks the next chapter in Hovione’s legacy of more than two decades in the U.S.,” said Marco Gil and Antonio Almeida, Co-Chief Executive Officers of Hovione. “This investment enables us to meet growing demand while further reinforcing our global leadership in pharmaceutical spray drying. Equally important, this technology sits within an integrated offering that extends from drug substance through drug product, giving customers a more direct and resilient path from early development to commercial. This is how we help them address poor solubility, one of the industry’s most persistent development challenges, and bring complex medicines to patients faster.”

The East Windsor campus will continue to expand over the next five to ten years, with plans to develop approximately 15 acres of adjacent property into a 125,000-square-foot manufacturing facility supporting additional laboratories, commercial-scale spray drying and drug product manufacturing. Customers can co-invest in this planned expansion to gain priority access to proprietary Hovione platforms, engineering know-how and accelerated capital deployment to accelerate their programs.

“89 Twin Rivers is a major step forward for Hovione’s U.S. operations and a clear expression of our long-term commitment to East Windsor and New Jersey,” said David Basile, Vice President of Technical Operations, Americas, at Hovione. “Our growth has been built on sustained investment in scientific expertise, technological innovation, advanced manufacturing capabilities, and talented people. As we look to the future, we will continue to strengthen this site as an innovation hub for pharmaceutical development and manufacturing, contributing to the competitiveness of New Jersey’s life sciences ecosystem and to a stronger U.S. manufacturing base.”

Hovione 89TR Inauguration_Spray Drying_ribbon cutting | Hovione

From left to right: Marco Gil (Co-CEO, Hovione), Janice S. Mironov (East Windsor Mayor), Debbie Hart (BioNJ President), António Almeida (Co-CEO, Hovione), David Basile (Vice President of Technical Operations, Americas, Hovione)

The site expansion is part of Hovione's international strategy to build a network of autonomous yet harmonized development and manufacturing sites across North America, Europe and Asia. Together with recent investments in Portugal and Ireland, the U.S. expansion supports regionalized supply, dual-site manufacturing strategies and greater supply chain resilience through consistent technologies, quality systems and specialized manufacturing expertise.

Honored guests East Windsor Mayor Janice S. Mironov and BioNJ President Debbie Hart participated in a ribbon cutting ceremony during a September 15 event inaugurating the facility.  

Today, Hovione partners with 19 of the world's 20 largest pharmaceutical companies, and it is involved in up to ten percent of medicines approved annually by the U.S. Food and Drug Administration. 
 

 

Also in the Press Room

See All

The investment includes both continuous and batch tableting capabilities, as well as connect spray drying with tablet production at its East Windsor campus. Hovione, a Portugal-based contract development and manufacturing organization (CDMO), plans to install a continuous tableting line at its East Windsor, New Jersey campus, adding drug product manufacturing capacity and an integrated pathway from amorphous solid dispersion production through commercial tablet manufacturing. The $35 million investment will bring the first ConsiGma CDC Flex system to Hovione’s recently opened 89 Twin Rivers facility. The line is expected to be commissioned in late 2027 and will support both continuous and batch operation at throughputs ranging from 1 to 200 kilograms per hour, according to the announcement. The system will allow customers to use the same equipment for development, clinical, and commercial production, with formulation development possible using as little as 1.5 kilograms of material. Hovione said the line will also be equipped for containment to 1 microgram per cubic meter to support the handling of highly potent compounds. The new capability will also connect Hovione’s spray-drying operations with tablet manufacturing at the East Windsor campus. The company recently opened a 31,000-square-foot facility at the campus with two commercial-scale spray dryers for manufacturing amorphous solid dispersions (ASDs), completing a $100 million investment in its New Jersey operations. Hovione said the integrated setup will allow customers to move from formulation and particle engineering through tablet production under one quality system, reducing technology transfer requirements and eliminating traditional scale-up between development and commercial production. The ConsiGma CDC Flex platform was jointly developed with GEA as part of a collaboration that began in 2022, the company said. The system incorporates automated process controls and process analytical technology for real-time monitoring during production. Hovione already operates continuous tableting technology at its Loures, Portugal site. In August, the company completed a more than €40 million expansion of its tablet development and manufacturing center there, adding a second commercial-scale tableting line and increasing the center's manufacturing area by 25%. The East Windsor installation will extend Hovione’s continuous tableting capabilities to the U.S. and expand its integrated drug development and manufacturing services for oral solid dosage products. Read the full article at Pharma Manufacturing 

Press Clipping
Pharma Manufacturing, 6 October 2026

Hovione to add $35M continuous tableting line at New Jersey site

Oct 06, 2026

Hovione, a globally integrated pharmaceutical contract development and manufacturing organisation (CDMO), will commission the world’s first ConsiGma CDC flex – a next generation continuous tableting line – at its East Windsor, New Jersey (USA) campus in late 2027. The line will be installed at 89 Twin Rivers, Hovione’s recently opened facility, expanding the company’s drug product capabilities and strengthening its integrated pharmaceutical development and manufacturing hub in the US. CDC ConsiGma flex system The project represents an investment of $35 million. Once installed it will create an integrated pathway from amorphous solid dispersion manufacturing via spray drying through commercial tablet production. The new flex will operate in continuous or batch modes across a very broad throughput range (from one to 200 kg/h). Customers will be able to develop a formulation using small quantities of material, down to 1.5 kg, and then run from very small clinical batches to large commercial batches using the same equipment. This is enabled by specialised design within the flex to effectively switch between continuous blenders of various sizes. Additionally, the line will be installed for containment to 1 µg/m³, supporting highly potent compounds. Continuous tableting is reshaping manufacturing of oral solid dosage medicines and is well suited to programmes in which speed, supply resilience and efficient use of high-value active pharmaceutical ingredients (APIs) are priorities. Inline process analytical technology (PAT) and automated controls also provide real-time quality monitoring. In parallel, the 2022 adoption of ICH Q13 regulatory framework, guidance specifically for continuous manufacturing of drug substances and drug products, provides harmonisation across the US, Europe and Japan. As of 2024, 17 products manufactured under the international guidance have been approved by the US Food and Drug Administration (FDA) alone.  Developed jointly with GEA, the ConsiGma CDC flex platform also incorporates SimpleCT, a suite of automation and control tools with smart interfaces that supports a single process from development to commercial supply. Designed for versatility and ease of use, these innovative developments simplify operation, improve efficiency and containment, and enhance operator safety. Read the full article at Pharma Press UK 

Press Clipping
Pharma Press Global, 6 October 2026

Hovione to commission world’s first ConsiGma CDC flex, bringing next-generation continuous tableting to the US

Oct 06, 2026

Key Takeaways Commissioning a US-based ConsiGma CDC Flex line enables end-to-end spray drying-to-tablet manufacture within a single site and quality system, reducing comparability and technology-transfer burdens. Elimination of conventional scale-up is enabled by using the same equipment from early development through commercial supply, minimizing engineering runs and conserving scarce API. Operational flexibility spans batch or continuous modes and 1–200 kg/h throughput, with scale adjustment achieved by switching continuous blenders rather than replatforming processes. High-containment design to 1 µg/m³ expands suitability for highly potent oral solid-dose programs while maintaining integrated development-to-commercial workflows. Regulatory momentum for continuous manufacturing is supported by ICH Q13 harmonization, increasing FDA approvals, and platforms leveraging inline PAT and automated control suites for real-time quality assurance. Hovione announced on Oct. 5, 2026, that it will commission the ConsiGma CDC Flex, a next-generation continuous direct compression tableting platform jointly developed with GEA. The investment is designed to link amorphous solid dispersion manufacturing via spray drying with commercial tablet production at a single US site operating under one quality system. The line will run in either continuous or batch mode at throughputs from 1 to 200 kg/h. Formulation development can begin with as little as 1.5 kg of material, and the same equipment can then support everything from very small clinical batches to large commercial runs, enabled by a design that allows the system to switch between continuous blenders of different sizes. The installation will also be contained to 1 µg/m³ to accommodate highly potent compounds. "Hovione will be the first company in the world to offer the ConsiGma® CDC Flex, bringing this next-generation technology with unprecedented flexibility, simplicity and cost-efficiency in continuous tableting," said Marco Gil and António Almeida, co-CEOs, Hovione, said in a press release. "This investment also advances our strategy of building integrated capabilities close to customers in key markets. By adding this new line at East Windsor, we are broadening access to this technology in the U.S. and giving customers a more direct and accelerated path for developing and commercializing complex oral medicines." What Does a Single Development-To-Commercial Line Change? For formulators and process engineers, the most consequential claim is the removal of traditional scale-up. Moving a process from development equipment to commercial equipment typically requires engineering runs, bridging work, and consumption of scarce API, all of which weigh heavily on early programs with limited material. "Installing the CDC Flex at 89 Twin Rivers makes continuous tableting part of an integrated US development and manufacturing workflow," said David Basile, Vice President of Technical Operations, Hovione, in the press release. "Customers can move from formulation and particle engineering to commercial tablets with one Hovione team and one quality system, eliminating traditional scale-up while gaining greater production flexibility, process control and supply continuity." Co-locating spray drying and tableting is also significant because amorphous solid dispersions remain a primary solubility-enhancement route for poorly soluble molecules, and transferring intermediates between sites or vendors adds technology transfer and comparability burdens. The new line builds on the company's earlier US expansion; Hovione recently completed a $100 million investment to bolster US capacity in particle design, amorphous solid dispersions via spray drying, and batch and continuous tableting. How Is the Regulatory Environment Shaping Continuous Tableting Adoption? The company points to the 2022 adoption of ICH Q13, which provides harmonized guidance for continuous manufacturing of drug substances and drug products across the US, Europe, and Japan. Hovione reports that, as of 2024, FDA alone had approved 17 products manufactured under the guidance. Speaking on ICH Q13, FDA's Kelley Burridge, PhD, "Perceived barriers to continuous manufacturing have been falling one by one," and noted an FDA publication showing faster approval times for products with continuous manufacturing elements than for comparable batch products. The platform incorporates inline process analytical technology and automated controls for real-time quality monitoring, along with SimpleCT, an automation and control suite intended to support a single process from development through commercial supply. For sponsors weighing supply resilience and regional sourcing, the East Windsor installation extends a capability that Hovione says only it currently offers as a contract development and manufacturing organization.   Read the full article at PharmTech.com  

Press Clipping
PharmTech, 5 October 2026

Can Continuous Tableting End Scale-Up for Complex Oral Drugs?

Oct 05, 2026

Also in Events

See All