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 a new Syringe Manufacturing facility.
The project involves converting a 120,000 SF former furniture and fabric manufacturing plant into a state-of-the-art syringe production facility. The initial phase will include two syringe manufacturing lines, two molding rooms, and supporting spaces such as labs, offices, gowning and locker rooms, a break room, and a warehouse. Future expansion plans include up to six syringe manufacturing lines. This fast-track project aims to launch operations in early 2026.
Beyond the new 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.
Key Challenges & Solutions
Roof Access & Edge Protection – Lack of existing edge protection delayed access due to site safety coordination.
Sprinkler System Hydraulics – M7, located at the end of the complex’s sprinkler main, faced a hydraulic shortage. Cyma collaborated with Genesis and FM to adjust the layout and reduce piping size, avoiding the need for a new service.
Fire Code Compliance – Cyma worked with the East Whiteland Fire Marshal to eliminate a 200-lb pressure test that would have impacted adjacent tenants.
Flooring Change – A last-minute switch from sheet vinyl to an epoxy Resuflor system disrupted MEP trades due to its five-coat application, moisture mitigation undercoat, and 72-hour cure time.
Ductwork Compliance – Existing ductwork initially marked for retention was found to have interior insulation, violating J&J standards. Full remediation was required.
Energy Code Compliance – Existing CMU walls failed to meet energy code requirements, necessitating insulation and furring out sections with electrical feeders and panels.
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.
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:
6,500 SF of new cGMP warehouse capacity
Two new 175 BHP boilers
Two new 128 ton chillers
A new clean compressed air system
A new WFI and CS Generation and Distribution system.
Six new roof top air handlers to support the new spaces.
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.
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.
Cyma Builders successfully completed the GMP production suites for one of our confidential clients! The purpose of this project was to expand upon the facility’s existing GMP production spaces with four new Grade B Gene Therapy suites as well as an additional freezer room.
We are proud to share that our team was not only able to accomplish the expansion successfully, but also overcome the project’s unique challenges in a seamless way.
Creating an Efficient, Workable and Easily Accesible Layout
One of Cyma’s initial tasks was to create an efficient and workable layout while also ensuring that all areas would be easily accessible from the GMP clean room’s walkable ceiling. There was an extensive effort to coordinate all trades in the ceiling and to ensure that all the ductwork, process piping, and mechanical system would be accessible from this ceiling. This was achieved utilizing BIM modeling and coordination sessions for a 10 week period at the onset of the project.
Overall, the client was very happy with the result as it is relatively easy to access anything from the walkable ceiling installed during this portion of the project!
Preventing Covid-Related Equipment Delays and Supply-Chain Disruptions
One of the main challenges of the project was dealing with supply chain disruptions and COVID related delays to the equipment. Cyma created a tracking matrix early in the job and coordinated with subs on all components to try and identify components that suffered delays as quickly as possible. Once they were identified, Cyma worked with the manufacturer to try and mitigate the delay and prevent the component from delaying the overall project.
In the end, Cyma was able to prevent any equipment related delays from affecting the overall delivery and integration of the production suites into the existing facility!
Expanding and Integrating New Infrastructure with Minimal Disruption
Another challenge on the project was actually segregating the project from the existing facility and ensuring there was no impact to existing GMP operations. This was achieved by creating a comprehensive utility shutdown matrix which allowed the facility to see when and how every project related shutdown was being performed on the project, and whether or not it would be disruptive to the facility.
The facility was then able to coordinate with their end users and Cyma to select a date that would have the least impact. During these critical shutdowns, Cyma would draft and circulate a method of procedures to further coordinate with the facilities maintenance team so they would know what tasks were being performed throughout the day of the shutdown.
This process was very helpful to both Cyma and the facility as it allowed the shutdowns to be well planned and adapt to unforeseen circumstances as needed.
Phase 2 Expansion has commenced and is off to an explosive start, both literally and figuratively! Breaking ground on this expansion took on a whole new meaning when the project team utilized explosives to blast through the existing bedrock.
All this effort will eventually lead to the foundation that will house a new aseptic manufacturing facility with the capacity to double their fill/finish capabilities.
