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Catalent Extends Global Commercial Spray Drying Capabilities In Europe

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Catalent, Inc, the leading global provider of advanced delivery technologies, and development and manufacturing solutions for drugs, biologics, gene therapies, and consumer health products, announced that it has significantly expanded the capacity of its global spray drying operations through an agreement with Sanofi Active Ingredient Solutions, an industrial platform of Sanofi, under which Sanofi will provide Catalent with access to spray drying manufacturing services for Catalent’s customers at Sanofi’s Haverhill, U.K. facility.

This agreement immediately extends Catalent’s global spray drying offering by making available to Catalent and Catalent’s customers the dedicated use of the existing Niro PSD2 and PSD4 spray driers at the facility. These spray driers are supported by dedicated clean area facilities for both solvent and aqueous processing of potent or non-potent drug formulations as well as a secondary vacuum dryer. Catalent is now able to offer spray drying solutions from early-phase development through clinical supply and all the way to fully scaled-up commercial finished dose form manufacturing in Europe.

Under the terms of this agreement, Catalent will also have access to the facility’s integrated quality control and analytical capabilities with scientific support resources, enabling an end-to-end approach for customers.

“This agreement not only gives Catalent access to spray drying capabilities at Haverhill and its state-of-the-art equipment, but also an experienced and skilled team at the site with expertise in commercial-scale spray dried dispersions, which are frequently used today to overcome the solubility challenges with many new medicines,” said Jonathan Arnold, President of Catalent’s Oral Drug Delivery business unit.

“Sanofi Haverhill is our center of excellence for spray drying technology. The site has over a decade of experience in spray drying operations for commercial manufacture. We welcome the relationship with Catalent and are delighted that Catalent is investing in the innovation and resources at our U.K. facility,” said Philippe Clavel, Head of Sanofi Active Ingredient Solutions.

Earlier this year, Catalent announced a $40M investment in its Winchester, Kentucky facility that includes adding commercial-scale spray drying with high-potent handling capabilities, as well as other increases to the site’s capacity and its formulation and controlled-release tablet and capsule manufacturing capabilities. The Winchester facility will work alongside the Sanofi Haverhill facility to enable transfer and scale-up of spray drying programs from Catalent’s specialized early-stage clinical development sites located in San Diego, California and Nottingham, U.K.

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Managing Quality and Regulatory Risks in Pharmaceutical Technology Transfer

Technology transfer moves more than manufacturing instructions. It moves process knowledge, supplier dependencies, labeling requirements, packaging specifications, and the evidence needed to demonstrate control. For medical device manufacturers, including those supporting drug-device combination products, these interfaces can become recurring sources of compliance gaps during site transitions, acquisitions, and remediation. The central problem is often not a missing procedure. It is a quality system that allows connected activities to change independently. A label revision may be approved while packaging artwork, supplier instructions, or production-system data still reflect an obsolete version. Staying inspection-ready requires manufacturers to manage these dependencies as one controlled system. Why Compliance Gaps Keep Recurring Findings are treated as documentation defects Revising a procedure can resolve an immediate discrepancy without changing the behavior that caused it. If unclear decision rights, weak escalation, or ineffective training remain, the same failure may surface elsewhere. Corrective and preventive action should distinguish the observed finding from its underlying cause and establish how effectiveness will be demonstrated. Ownership is divided across connected functions Quality, Regulatory Affairs, labeling, packaging engineering, operations, suppliers, and digital-system owners often maintain separate workflows. Each team may complete its assigned task while an interface remains uncontrolled. For example, changing an instruction for use can affect packaging configuration, translations, technical documentation, inventory disposition, and release controls. Transitions expose unresolved weaknesses Acquisitions and site transfers can introduce conflicting procedures, incomplete knowledge transfer, or different assumptions about validated processes. Regulatory changes add further demands. When these events coincide with CAPA or change-control backlogs, teams may prioritize administrative closure over risk reduction. Without a coordinated impact assessment, local fixes can create new gaps downstream. Establish the Regulatory Baseline Inspection readiness starts with knowing which requirements apply to the product, activity, and market. Pharmaceutical, device, and combination-product obligations are not interchangeable; transfer planning should identify the applicable requirements rather than assume one quality framework covers every operation. 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Use change control as the integration point. Before approval, evaluate effects on regulatory submissions or notifications, technical documentation, supplier controls, packaging performance, validation, electronic master data, inventory, and training. Record both identified impacts and justified decisions that particular activities are unaffected. During technology transfer, define readiness gates before production or release responsibilities move. These should address the transfer of process knowledge, acceptance criteria, receiving-site capability, required qualification or validation, approved documents, and personnel competence. The appropriate evidence depends on the product and process; a generic checklist cannot replace a documented assessment. Finally, verify implementation where the work happens. Confirm that current instructions are available, suppliers received approved requirements, systems contain correct versions, and affected personnel can perform their tasks. A signed approval is not evidence that every downstream change took effect. Mistakes That Undermine Inspection Readiness Closing CAPAs on task completion alone: Effectiveness checks should test whether the underlying failure has been controlled. Updating labels in isolation: Assess packaging, supplier, system, documentation, and inventory consequences. Counting closures instead of evidence: Dashboards need defensible records behind their status indicators. ...

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