Formulated Solutions completes investment and expansion project

The CDMO significantly increases its footprint, capacity and capabilities to meet current and future demand

The expansion applies to all areas of new product development and manufacturing of branded Rx, over-the-counter (OTC), new drug application (NDA) and medical device products.

Investments included the acquisition of 100,000 sq. ft of GMP component and raw material warehouse space complete with GMP raw material sampling suites and a dedicated NFPA 30B-compliant aerosol storage area.

Additional investments were made in new raw material pre-weigh suites, increasing the efficiency of product flow through the production facility.

The company then significantly expanded its liquid and semi-solid blending capacity by installing several custom-designed, jacketed, pressure-rated, blending vessels, complete with internal homogenisation.

In one production suite, the company installed new high-viscosity bulk intermediate filling heads, dramatically increasing the breadth and range of aerosol solutions it can offer partners.

To further expand its capabilities in semi-solid dispensing solutions, Formulated Solutions built and installed a custom-designed monoblock production line for the filling and assembly of high-viscosity-capable, multicomponent airless pumps.

Among the company's most complex additions was the installation of a new ‘plant within a plant’, devoted exclusively to the high-speed production of nasal sprays.

The company’s new ISO 8 manufacturing suite now houses custom-designed pre-weigh, blending, cleaning, filling and assembly areas with production rates reaching up to 200 units per minute.

Further investments included 34,000 sq. ft mezzanine and warehouse expansions to support future growth.

Formulated Solutions' VP of Marketing and Partner Innovation, Scott Carpenter, said the company's ability to anticipate large-scale of growth, "has long been part of our business model”.