Aptar Pharma, a US-based provider of dispensing solutions to the pharmaceutical industry, expanded its manufacturing facility in Congers, New York, to address the increasing demand for proprietary drug delivery systems from prescription and consumer healthcare customers in North America.
The facility expansion was announced in March 2024 and completed in September 2024.
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The expanded facility upgraded Aptar Pharma’s warehousing, clean room and manufacturing capabilities.
Aptar Pharma’s global expansion plan details
The expansion of the Congers facility in North America was part of Aptar Pharma’s broader global injectables expansion programme, announced in 2020, to substantially increase capacity across multiple product lines within Aptar Pharma.
The global expansion plans included an injectables expansion programme in France and new manufacturing sites in Suzhou, China, and Mumbai, India.
The expanded site supports Aptar’s “local for local” approach, addressing the sustained customer demand in the region and ultimately benefitting patients.
Aptar Pharma’s expanded manufacturing facility details
The new expanded capacity was accommodated within the building extension at the current Aptar Congers site.
The expansion added 28,500ft² (2,648m²), which is dedicated to manufacturing Aptar Pharma’s PremiumCoat® Ethylene Tetrafluoroethylene (ETFE) film-coated stoppers for the injectables market.
The production process for the stoppers includes on-site moulding and trimming in the new ISO-7 clean room, while finishing and automated vision inspection are performed in an ISO-5 clean room.
The production of PremiumCoat® solutions at Congers is included in the same Drug Master File as Aptar’s manufacturing sites in Granville and Brecey, France.
The site supports the manufacturing and development of drug delivery systems, including the proprietary Unidose nasal spray systems used for naloxone, Narcan® and neffy® (epinephrine nasal spray), through the new moulds and assembly lines in cleanroom settings.
Furthermore, a new assembly line has been installed in the environmentally controlled good manufacturing practice production area to increase the manufacturing of bag-on-valve (BOV) technology to meet the rising demand for nasal saline solutions.
The facility also includes a clean room extension for child-resistant senior-friendly closure solutions, supporting child-resistant packaging for nasal decongestant sprays.
Aptar Pharma’s existing Congers facility details
The 160,000ft2 (14,864m2) Conger’s facility employs around 350 employees, and has been operational with eight ISO-certified clean rooms since 2002, initially manufacturing Aptar Pharma’s VP3 pumps. It has 14 injection presses and 25 machines.
The site currently produces a diverse range of patented drug delivery products for nasal and injectable delivery routes.
Additionally, the facility also manufactures drug delivery solutions for the treatment of epilepsy, diabetes, depression, migraines, allergies and more.
Marketing commentary on Aptar Pharma
Aptar Pharma employs more than 13,000 staff across 20 countries. It serves multiple end markets including beauty, beverage, food, home care, personal care and pharmaceutical.
The company leverages its market expertise, proprietary design, engineering and science to develop innovative solutions for leading brands, impacting the lives and well-being of millions.
Aptar’s product technologies span a range of applications including active packaging, airless packaging, bi-injection, bonded aluminium to plastic, BOV, child-resistant/senior-friendly, e-commerce-capable, food protection, preservative-free-systems, SimpleCycle® TPE Valve, SimpleSqueeze® Elastomeric Flow Control and tethered closures technology.
The products are recognised for setting benchmarks in dispensing, sealing and active packaging innovations.
Aptar’s PremiumCoat® ETFE film-coated vial stoppers and syringe plungers use a high‑purity elastomer, advanced manufacturing methods and an ETFE film coating to help preserve the stability of sensitive injectable medicines.
By lowering levels of extractables and leachables, PremiumCoat® enhances drug compatibility, supports faster development timelines and contributes to patient safety. These solutions are designed to work with the most widely used glass primary containers and standard filling equipment.