In May, members of the Cyma Builders team attended the 2025 ISPE Delaware Valley Chapter event at Lincoln Financial Field. The event provided a valuable opportunity to reconnect with industry colleagues and engage with new vendors, clients, and partners. It was a dynamic setting for networking, collaboration, and staying current with the latest in pharmaceutical engineering.
Exela Pharma Sciences, LLC has selected Cyma Builders as the EPCM lead for multiple facility projects in Lenoir, NC. Exela, a developer and manufacturer of proprietary and generic sterile injectable products, first engaged Cyma in summer 2024 for renovations throughout their campus of buildings.
The biggest projcet involves converting a 120,000 SF former furniture and fabric manufacturing plant into a state-of-the-art production facility. The initial phase will include production lines along with supporting spaces such as labs, offices, gowning and locker rooms, a break room, and a warehouse. This fast-track project aims to launch operations in 2026.
Beyond the new production facility, Exela has also tasked Cyma with leading major infrastructure upgrades, filling line improvements, and building expansions across other Lenoir sites. Cyma is currently advancing through the design phase, with construction staffing planned for the second half of 2025 and into 2026.
Cyma Builders was onboarded to execute a fast-tracked Design-Build Lab Project to support the PC&D group’s relocation from Fort Washington to Malvern. The project was highly schedule-driven to meet the business segregation deadline of Kenvue from Johnson & Johnson Innovative Medicine. A purchase order for enabling activities was received in late March 2024, with design continuing through the summer and the new M7 suite scheduled for turnover by the end of 2024.
To clear the M7 Suite for construction, the Avantor group—using M7 as a storage and operational hub—had to be relocated. Site leadership designated M10 as Avantor’s new location, a building under TSA oversight. A design-assist approach was implemented to segregate the TSA Warehouse using a pre-approved floor-to-deck cage bisecting the racking system. The layout also incorporated double doors with clearance for Avantor’s forklift, a forklift charging station, and a security package. Securing TSA approval for these modifications required significant coordination from Cyma Builders. With the warehouse completed, Avantor vacated M7 in late July 2024.
While the design team focused on critical path packages—including long-lead equipment, demolition, and underground/structural/IFP—construction mobilized at M7 to begin demolition. The absence of as-built drawings and visible cleanouts necessitated a video scope through a toilet to map underground piping. Findings prompted major sanitary layout changes, implemented by late August 2024. Attention then shifted to reinforcing the roof deck to support four new Trane AHUs, an exhaust fan, and a Condair Steam Generator. Safety concerns arose when lead paint was discovered on the existing deck, complicating welding operations. Crews wore respirators, containment was built, and negative air pressure was established before proceeding with welds, limiting other trades’ progress through September. Once weld inspections were passed, MEP trades and carpenters worked six 10-hour shifts per week through project completion. The PC&D group successfully relocated to M7 at the turn of 2025, though the project presented several challenges.
Despite these obstacles, the project was delivered on schedule, ensuring PC&D’s timely relocation to the new suite.
In September, Cyma Builders participated in several career fairs, including events at Penn State, Thomas Jefferson University, and Pennsylvania College of Technology. Cyma conducted interviews for both internship and full-time positions, reinforcing its commitment to cultivating the next generation of talent and strengthening the company’s future.
On Wednesday, June 26, 2024, Cyma Builders and its trade partners hosted a steel topping-out ceremony to celebrate a significant milestone in the Almac NAHQ Expansion Project. This timeless tradition places the final major piece of structural steel, symbolizing a key achievement in the construction process.
Contractors and client personnel gathered to witness the milestone and joined a celebratory lunch after installing the steel.
Cyma Builders is excited to continue progressing toward the next phases of this project!
Cyma recently held a site safety lunch and learn event for its project with DSM, recognizing contractors for their proactive “good catch” submissions and safety observation reports. These sessions addressed a range of site-specific safety topics and included a mandatory “Focus Topic,” offering contractors an opportunity to meet OSHA compliance requirements while reinforcing critical safety concepts and practices.
For July, the Focus Topic centered on Bloodborne Pathogens Awareness and Exposure Control Planning, ensuring everyone on-site stays informed and prepared.
For this project, we transformed a warehouse into a state-of-the-art dynamic laboratory space, complete with new lab areas, mechanical mezzanines, and upgraded utilities.
The project encompassed diverse construction and renovation tasks to meet the client’s requirements. Central to the transformation was the creation of new lab spaces, including supporting facilities like restrooms and a loading dock area. Key features of the fitout included a 10,000 square foot mezzanine that required robust footings and steel dunnage. The new mezzanine was constructed to accommodate essential mechanical equipment such as rooftop exhaust fans and air handler units. Extensive ductwork ensured efficient airflow and ventilation throughout the facility.
Upgrades to the electrical service were crucial, necessitating collaboration with utility companies and ownership for installation of new distribution gear and dedicated panels for lab equipment. Additionally, new drainage and utility systems, including gas services, were integrated to support lab operations.
Despite challenges like excavating and installing mezzanine footings and coordinating utility upgrades with local authorities, the project excelled. Through meticulous planning and innovative solutions, disruptions were minimized, ensuring seamless operations. We are very pleased that the project not only met but exceeded the expectations of the client, providing a versatile and state-of-the-art research environment for years to come.
Cyma Builders proudly announces the successful completion of Phase 2 at August Bioservices, marking a milestone in our commitment to construction excellence and client satisfaction.
Expanding GMP Production Spaces and cGMP Warehouse Capacity
The primary objective of Phase 2 was to augment the existing GMP production spaces and cGMP warehouse capacity at the facility. This involved constructing and finalizing the cGMP warehouse, completing CNC and Process corridors, and installing necessary MEP infrastructure.
The culmination of Phase 2 resulted in several key accomplishments:
These enhancements provide the foundation for improved operational efficiency and capacity expansion, empowering August Bioservices to meet growing demands and advance their mission.
Overcoming Challenges with Precision and Expertise
Despite challenges, such as the presence of extensive limestone bedrock and the proximity to the Colonial Natural Gas Pipeline, we successfully executed blasting activities. This was achieved through meticulous planning and collaboration with subcontractors and pipeline owners, ensuring zero incidents.
Following blasting operations, we swiftly transitioned to constructing the building shell using a steel superstructure with precast panels for durability. Simultaneously, interior fit-out work commenced on the warehouse, and despite supply chain delays, our proactive approach and strategic partnerships mitigated potential setbacks.
Looking Ahead: Phase 3 and Beyond
As we celebrate Phase 2’s success, we look forward to Phase 3’s growth. Scheduled to start in late Q1, it will introduce two formulation suites for custom filling lines. Our team remains dedicated to delivering excellence at every stage of the project, driving innovation and progress in the field of construction.
The successful completion of Phase 2 at August Bioservices underscores our commitment to quality, safety, and client satisfaction. We extend gratitude to stakeholders for their collaboration, shaping the future of construction excellence. Stay tuned for updates as we proceed to the next phase!
For inquiries or to learn more about our services, please visit our website or contact us directly.
Cyma Builders, Almac, & the design partners gathered to celebrate the groundbreaking of the Almac North American Headquarters Expansion Project (Souderton, PA). This transformative initiative will enhance the existing campus by adding an impressive 113,410 square feet, increasing parking capacity, and implementing substantial site and utility infrastructure improvements.
Read Almac’s announcement of the ceremony here.
Cyma Builders completely renovated an existing pharmaceutical production space for August Bioservices, helping to facilitate their future business goals. The client purchased the facility with the intent of developing an extensive CDMO capability located in the middle of the United States.
The initial step was to revamp the existing facility to enable manufacturing operations while the future buildings were being designed. This involved overhauling the mechanical and electrical systems, and installing new clean process utilities to support the filling process that was intended for the site.
Significant work was also done on the existing equipment mezzanine above the suites, which included removing of AHUs and installing of new ductwork. This was coordinated with other utilities and equipment to ensure clear maintenance access.
Additionally, Cyma assisted the client in arranging for a new electrical service from the public utility company, capable of supporting the increased power needs from the current renovation and future expansion projects.
This project was executed during the COVID-19 pandemic. As a result, the project suffered significant challenges related to supply chain issues which affected stainless steel piping, electrical breakers, and mechanical infrastructure.
