Halo Pharma is expanding manufacturing capacity at its Whippany, NJ, facility with the addition of a Gerteis Macro-Pactor, a high-throughput roller compactor designed to handle complex formulations and improve process efficiency.

The CDMO, known for its solid-dose development and production services, said the investment will strengthen its ability to support both early-stage programs and commercial-scale manufacturing. The new equipment will also complement the site’s existing Gerteis Mini-Pactor, which is used for development, clinical supply, and small-scale commercial batches.

The Macro-Pactor is expected to be operational in the first quarter of 2026. The system’s dry‑granulation performance, improved powder-flow characteristics and reduced variability are aimed at broadening Halo Pharma’s capabilities, particularly for moisture‑sensitive active ingredients, high‑drug‑load formulations, poor‑flowing powders, potent compounds and modified‑release products.

“One of the major advantages of adding the Macro-Pactor is that the process parameters established during early-phase development translates almost directly into larger batch sizes,” said Satish Shetty, Senior Director, Product Development & Technical Services at Halo Pharma. “Since the equipment is engineered for both development and commercial throughput, it eliminates the typical disconnect between small-scale R&D and large-scale manufacturing, reducing scale-up risk, timelines, and the need for reformulation.”

Shetty added that the equipment’s closed, dust‑contained design will limit operator exposure, cut down on product loss and support regulatory-compliant handling of potent materials. The system’s integrated safeguards and reduced open processing steps are expected to improve control over manufacturing operations involving sensitive or controlled substances.

The Macro-Pactor will also bolster the company’s technology‑transfer processes. With data-rich control of critical parameters and compatibility with existing upstream and downstream systems, the company expects smoother transitions from development batches to commercial-scale production, reinforcing its Quality by Design framework and coordination across R&D, process development, manufacturing and quality groups.