Catalent Pharma Solutions’ Consumer Health business has completed the first phase of a multi-million dollar expansion of its facility in Aprilia, Italy. The expanded site offers service from product conceptualization to formulation, development, production and packaging. Products manufactured at the Aprilia site include Vegicaps capsules, easy-to-swallow plant-derived capsules that are free from animal derivatives and gluten.

“We needed to expand capacity for both traditional gelatin and Vegicaps capsules to ensure reliable supply of strong customer demand,” said Gerry Purnell, European commercial director for Catalent’s Consumer Health business. “Customers are increasingly considering Vegicaps capsules because the technology accommodates a wide range of formulations and provides access to markets that require products free from animal derived gelatin.”

The site has been expanded to include a new dedicated gelatin production area and new encapsulation machinery for traditional gelatin production and Vegicaps capsules, increasing output by almost one third. Catalent has also added key processing equipment, such as a new turbo emulsifier to replace open roll-milling equipment. Capacity within inspection and drying areas has been increased and workflows and environments have been reviewed and enhanced to maintain safety and cGMP.

Stefano Arena, general manager of Catalent’s Aprilia site, said, “The improvements have been approved by the appropriate regulatory authorities, and we will continue to expand our facility in Aprilia throughout 2011 to bring more products, such as chewable capsules, to market. The ongoing expansion will not only benefit our customers in the consumer health market, but will also allow us to offer more services to the pharmaceutical and cosmetics sectors too.”