- PCI Pharma Services is investing over $1 billion across its US and European operations to expand sterile fill-finish and drug-device combination capabilities.
- A $100 million San Diego project and multiple site expansions will increase capacity across fill-finish, packaging, and development services.
PCI Pharma Services announced a series of infrastructure investments exceeding $1 billion across its US and European operations to expand its sterile fill-finish, advanced drug delivery, and contract manufacturing capabilities. The investments are aimed at supporting pharmaceutical manufacturers seeking US-based supply chain resilience and integrated CDMO services from clinical development through commercial production.
A central component of the plan is a $100 million expansion at PCI’s San Diego campus. The project will add a high-speed isolator filling line for ready-to-use prefilled syringes and cartridges, expected to be operational in the first half of 2028. The addition will more than double the site’s existing capacity and build on its current production of more than 45 FDA-approved products.
At its Bedford, New Hampshire site, PCI is commissioning a GMP-ready isolator vial and lyophilization line capable of producing batch sizes of up to 300,000 vials at 400 units per minute, with an annual capacity of 33 million vials. The company is also introducing a dedicated high-potent sterile fill-finish line at the same location. Across its US facilities, PCI has expanded automated visual inspection systems supporting more than 70 million prefilled syringes and cartridges and 40 million vials annually.
PCI is also investing in drug-device combination assembly and packaging infrastructure at its Philadelphia and Rockford sites. These upgrades, scheduled to come online over the next six months, will increase capacity for autoinjector assembly, with total US capacity expected to exceed 250 million units per year by 2027. The sites also provide packaging capabilities for oral solid doses and injectables, including cold chain storage and large-scale commercial supply.
In parallel, the company is establishing Development Centers of Excellence in Bedford, New Hampshire and León, Spain, focusing on formulation, analytical services, lyophilization, and drug-device combination development for biologics and small molecules.
“Backed by over $1 billion in global infrastructure investment and decades of operational expertise, PCI’s multi-year journey to bolster its domestic manufacturing footprint allows us to meet growing customer demand for innovative drug product and drug delivery solutions.”
Salim Haffar, CEO of PCI Pharma Services
