The medicines we develop and deliver to our customers help one million patients each day. With an increasing demand for our services, expertise and capabilities, comes a commitment to continuously expand our products and services. This is why we have been making unprecedented investments in our network of sites and capabilities around the world.
Our investment is not just about adding capacity—it’s about enhancing capabilities across our Pharma Services business. By drawing on the collective expertise from businesses across Thermo Fisher, expanding our network of best-in-class facilities, and strengthening our workforce with exceptional talent, we provide solutions to our customers that enable them to accelerate innovation and productivity and get medicines to their patients faster.
Learn more about our newly expanded capabilities below.
To support increasing demand for viral vector development and manufacturing services, Thermo Fisher is expanding capacity with construction of a new commercial manufacturing site in Plainville, Mass. The 290,000-square-foot facility will more than double the company’s commercial viral vector capacity to support customers who are developing and manufacturing gene therapies and vaccines to address unmet medical needs. Construction at the Plainville site will be complete in 2022, adding more than 200 jobs and complementing new or recently expanded capacity in Lexington and Cambridge, Mass., and Alachua, Fla. The Plainville site will offer a flexible and scalable configuration of laboratory and production suites co-located with adjacent warehousing and office space. An onsite engineering laboratory will help customers develop turnkey production platforms that enable them to rapidly transition to commercial-scale operations when ready.
Building on a 12+ year track record of supplying first-in-human clinical materials at our Alachua, Florida, site, we’ve invested over $3 million into an expansion that will double the upstream process development capacity, establish commercial QC testing, and offer a new offsite warehouse space. The expansion of this site will allow for more at scale development, enabling better technology transfer to GMP and increasing the probability for success for our clients’ gene therapy products. The expansion will ultimately enable our clients to bring more advanced medicines to patients.
Our $93 million investment in expanding our site in Lexington, Massachusetts, includes full renovation of a 50,000-square-foot facility for viral vector manufacturing and commercial manufacturing of viral vectors. The renovation added eight new drug substance suites and one new drug product suite, a GMP manufacturing support area, new QC labs, a manufacturing sciences lab, short-term warehouse space and office space. Through this investment, we are accelerating advancements in gene therapy and enabling our clients to get these transformative medicines to patients in need, increasing the number of patients benefiting from breakthrough medicines for rare and complex diseases.
Our investment of $40 million in added capacity at our Cambridge, Massachusetts, site further expanded our Viral Vector Services’ CDMO services, offering customers increased access to capacity at a variety of scales and with a personalized manufacturing approach that is focused on safety, quality, process robustness and fulfillment of their program goals. Opened in the fall of 2019, this expansion added four drug substance suites and one drug product suite, plus additional manufacturing support space and utility area.
To enhance our offering with expanded capabilities in order to meet the growing demand for biologic therapies, we’ve entered into a strategic partnership with CSL. Under the agreement, we’ll become CSL’s strategic pharma services partner supporting their product portfolio across our network with capabilities, including drug product development, sterile fill/finish, packaging and clinical trials logistics. Additionally, CSL will transfer operations and oversight of its state-of-the-art biologics manufacturing facility, currently under construction, in Lengnau, Switzerland, to Thermo Fisher. when construction is completed in mid-2021. Until mechanical completion of the site, we will operate as two separate companies.
With the addition of the Lengau site to our network, we gain access to a world-class facility to support highly flexible bioproduction technologies, including Single-Use and Stainless Steel, providing a pathway from development to large-scale production. This will enable our customers to easily get started with us and stay with us as their needs expand.
To learn more about this unique partnership, see links below.
Our $50 million investment in our St. Louis, Missouri, site increased manufacturing space by 62,000 ft2, doubling production capacity. At the end of 2019, the first GMP batch produced in the new facility met all client acceptance criteria. The expansion provides infrastructure that will allow us to anticipate and enable future expansions to occur even faster. The new capabilities also substantially increase our ability to meet the clinical and commercial manufacturing needs of our growing client base, helping us advance medicines to patients in need.
The acquisition of our Cork, Ireland, facility expanded our world-class API development and commercial capabilities for customers around the world. Combined with the unique offerings across our network, the site’s capabilities enables our customers to help patients with a range of diseases and will allow us to bring important new products to market. The additional API capability and capacity also increases our Quick to CareTM integrated offering for drug substance and drug product to speed up the development process and simplify our customer’s supply chain.
Phase III Commercial spray drying is now available via the newly constructed MS-400 facility within our Florence, South Carolina, site. This new addition in scale means we can now offer full development capabilities by utilizing our network in Bend, Oregon, and Milton Park, UK, and late phase/commercialization services for spray drying. Spray drying offers a solution for products with bioavailability challenges.
Lab of the Future
Thermo Fisher has invested $55 million in its Greenville, NC manufacturing site in 2019 to expand its capabilities and capacity for customers and the patients they serve. An investment in enhanced capabilities brings a commitment to build our workforce to strengthen our collaborative culture, deliver superior customer service and supporting local communities through growing career opportunities. One of those investments is the new Lab of the Future. The new Lab of the Future is a modular QC laboratory designed with Lean Manufacturing principles, state-of-the-art instrumentation, full instrument connectivity, laboratory automation and a leading-edge Informatics system to enable efficient and timely analytical results.
Pre-Filled Syringes (PFS)
The medicines we develop and deliver to our customers help one million patients each day, and the demand for our services, expertise and capabilities continues to increase. Our expanded capacity and capabilities address the growing need in the industry for high-quality sterile fill / finish services, which is being driven by the growth of biologic therapies. Adding the pre-filled syringes (PFS) capability is part of this expansion. The PFS market has increasing potential because it allows patients to treat themselves from home. It is convenient, affordable, patient-safe and accurate.
Virtual Training Center
Part of a $55 million investment in our Greenville, North Carolina, site, the new industry-leading Virtual Training Center is equipped with virtual reality and augmented reality capabilities to help advance the onboarding and training of personnel who will work on the sterile injectables drug production lines. The Virtual Training Center decreases training time from approximately a year to only four months, increases knowledge retention, and decreases the risk of deviations.
Our $4.4 million investment to expand our Suzhou, China, facility addresses the growing demand for drug development supply chain services and focuses on high quality primary and secondary packaging solutions for our customers. Part of our Clinical Trials business, the site offers a full suite of services and will enable local innovators to draw upon our global world-class integrated network to help them accelerate innovation and productivity and drive growth as they bring their products outside of China to patients around the world.
We invested $3 million to build a new state-of-the art center in Buenos Aires, Argentina. Opened in August 2019, the facility allows us to offer our expertise and capabilities to local clients with a focus on high quality secondary packaging solutions. The new site provides services in the areas of clinical trial support, including GMP storage, local labeling, secondary packaging, comparator sourcing, and handling and distribution of ambient and cold chain clinical trial supplies through to returns management.
In May 2019, we opened a new packaging and distribution facility in Ahmedabad, India, to better serve customer growth in India and their increasing need for clinical trial support focused on local products for India’s market. The facility addresses the growing demand for development supply chain services and specializes in high quality primary and secondary packaging solutions.
We announced that we will open a new $35 million state-of-the-art pharma services supply chain facility in Rheinfelden, Germany. The site will feature the latest technology and modern infrastructure to significantly increase European capacity for cold and ambient clinical trial materials in support of complex clinical research and to meet the growing needs of customers. The 8,000m2 facility will be scalable for mixed-use space, provide a strategic logistical location for shipping either by road or air, and has the option for an additional expansion that could double the footprint of the site.