Behind the Innovation
Avantor recently launched a consolidated single-use fluid-handling operations and logistics hub in Devens, MA., to meet growing single-use demand amid increasingly complex customization needs in the bioprocessing industry.
In the aftermath of COVID-19, global demand for single-use components, such as bags, tubing and connectors, has surged, often resulting in sourcing delays that disrupt production timelines and increase costs. A shortage of sterilized assemblies, for example, can bring manufacturing runs to a standstill.
Another problem customers face is scalability as they move from clinical trials to commercialization. This is in part driven by a lack of standardization across suppliers, which leads to customized workarounds for compatibility that require increased QC and validation time.
To address this, Avantor opened a 175,000-square-foot climate-controlled distribution center in Devens, MA, strategically located adjacent to the company’s single-use fluid-handling manufacturing facility, to meet our customers’ current and future needs and improve efficiency.
“Avantor is creating a secure, redundant supply chain by co-locating fluid-handling manufacturing and distribution in Devens,” explained Rasheedia Aigoro, VP of Manufacturing Operations and Supply Chain with Avantor. “Our Operations, Quality, Design Engineering, and Product Management teams partner with our customers to understand their operations and provide critical components for their single-use assemblies to reduce lead times and provide a resilient supply chain.”
The Devens site is an important part of Avantor’s global fluid-handling network, which is designed to deliver consistent product quality and sterility worldwide while remaining responsive to regional needs. With a component library of 14,000 vendor-agnostic parts, Avantor offers fully bespoke solutions designed for specific bioprocessing applications, including custom components and disposable skid systems that meet exact process requirements.
“The expanded facility, with more than 7,500 pallet spaces, complements Avantor’s existing manufacturing site by providing storage space for raw materials, as well as quality control and distribution capabilities, ensuring we can deliver our single-use products across North America with reliability and precision,” said Jim Eisner, Manager of Warehouse Operations.
Embedding Quality Controls in the Process Upfront
Avantor builds quality into every step of the single-use fluid-handling value chain by identifying and eliminating potential hazards upfront. “That means building ISO-classified cleanrooms with validated equipment, performing inspection and testing as required, and releasing product only with full traceability,” Keith Shanahan, Director of Quality for Avantor Fluid Handling, explained.
Operational enhancements include ISO-7 certified cleanrooms, standardized gowning, aseptic handling, equipment, and packaging processes, digitized batch records, and soon-to-be-implemented AI-driven inspections to ensure order accuracy. Electronic Batch Records will be introduced at Devens in 2026, strengthening traceability and quality assurance across operations.
In the last 12 months, Avantor has also made several improvements to its Devens, MA manufacturing site, including a significant increase in capacity, with the ability to expand further to support customer demand.
Together, Devens' manufacturing and distribution footprint comprises nearly 200 employees, including quality experts, engineers, customer service representatives, material handlers, clean room technicians, and maintenance technicians. On average, the team builds 1,400 assemblies daily.
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