Author: Vivian Xie 20th February 2026

The US pharmaceutical manufacturing sector faces a pivotal moment at the start of this new year. Demand for innovative solutions has never been greater, but geopolitical tensions and labor shortages have had a significant impact on the journey that brings those solutions to the end user. 

At a glance, two critical issues stand out: the surging demand for pharma packaging solutions and the increasing risks which come with a reliance on overseas supply chains. Addressing these challenges requires a strategic rethink of several key areas to ensure long-term stability and competitiveness, by taking collaborative new approaches to production models, partnerships, and reshoring. 

With events like CPHI Americas offering countless opportunities for this kind of collaboration, not only all along the pharma supply chain but across the continent, innovative ways to address to these challenges are in easier reach than ever before. Read on to learn more about the issues that American pharma’s manufacturing and reshoring sector are facing, and what is being done to meet the moment. 

Pharma Packaging Solutions: Growing Demand vs Labor Supply 

The demand for pharma packaging solutions is projected to reach $99 billion by 2034, almost double the current figure. This growth is driven by several factors, including the rise of biologics, personalized medicine, and the increasing need for sustainable and patient-centric packaging. However, this surge in demand comes with its own set of challenges. 

Labor Shortages and Operational Bottlenecks 

According to a report by the National Association of Manufacturers, 77% of manufacturers find it a struggle to attract and retain a quality workforce (NAM, 2025) [1]. In the pharmaceutical sector, this shortage is acutely felt in more specialized areas, such as packaging,  and quality control, and the development and manufacturing of advanced therapeutics, where strict regulatory standards and technological specifications require a skilled and oftentimes niche pool of talent. 

According to a 2023 study conducted by the Deloitte Center for Health Solutions [2], 66% of 105 surveyed biopharma supply chain leaders state that, despite the importance of recognising digitisation as a business imperative, many companies are still at a loss in how current roles and skills throughout the pharmaceutical industry must evolve. The acquisition of labor is thus largely reactive, with specific skills being hired in the short-term rather than developing long-term talent pools that reflect a rapidly evolving industry. 

“People have options – they can go into tech, law, or any number of other fields. In the CDMO sector, we face the same challenge,” 

stated Jack Shute, Managing Director at Vector Talent, in a roundtable discussion held at CPHI Frankfurt 2025. 

“Many graduates come out of university and lack awareness on CDMOs and the pharma services sector. It’s essential to educate them about these areas. Similarly, the industry as a whole finds itself in this position when it comes to data and AI – companies simply do not know about the opportunities for data and AI in pharma with the right talent.” 

Operational bottlenecks further exacerbate the problem; as demand for pharma packaging solutions grows, manufacturers struggling to scale their operations efficiently. One recent survey from The Pharma Letter [3]showed that contract and budget negotiations alone are the top pain point for an unbelievable 92% of clinical trial sites. Outdated production models and a lack of investment in automation and digital technologies are key contributors to these bottlenecks. Pharmaceutical moves like those of Pfizer and PostEra, AstraZeneca and China’s CSPC, and Eli Lilly and Nvidia point to larger trend of large-scale adoption of AI-native infrastructure in pharma, and the CDMO space must be ready to reshape how they enter such partnerships with the right technologies a topic covered in more detail in the 2026 Pharma Trends Outlook Report [4]. 

Market Volatility and the Need for Resilience 

Driven by the fluctuating cost of raw materials and continued disruption to global supply chains disruptions, a volatile marketplace adds another significant layer of complexity to the sector. While the COVID-19 pandemic exposed major vulnerabilities in the pharma supply chain, disruptions have not abated in recent years, whether due to ongoing global conflicts or natural disasters, among many other causes.  

To address these challenges, US pharmaceutical manufacturers will need to rethink their existing production models and partnerships. Investing in automation, digital transformation, and workforce development can help alleviate labor shortages and operational inefficiencies. Additionally, fostering closer collaborations with packaging solutions providers can leave them better equipped to meet growing external demand. 

The Path Forward: Building Resilience in US Pharmaceutical Manufacturing

The pharma manufacturing sector may be facing significant challenges, but that doesn’t make them insurmountable. Organizations who are concerned about how to address the impending changes can begin planning for them now by addressing some key strategies which will not just help them futureproof their operations but also improve their broader business prospects.  

• Investing in Workforce Development: Building a skilled workforce is a crucial way for businesses to meet growing demand and ensure compliance with regulatory standards. 
• Embracing Automation and Digital Transformation: Leveraging advanced technologies can help manufacturers streamline their operations, reduce costs, and improve efficiency. 
• Reshoring Production: Moving physical production back to the US can reduce reliance on volatile overseas supply chains and improve resilience. 
• Fostering Collaboration: Strengthening partnerships with existing suppliers, technology providers, and industry peers can drive innovation and create new opportunities for growth.

As the industry navigates these challenges, businesses need to take every opportunity to connect and network across the industry. Events like CPHI Americas play a crucial role in driving progress and fostering collaboration, bringing together stakeholders from across the pharmaceutical value chain to offer a platform for sharing insights, exploring solutions, and building the partnerships needed to overcome the industry's most pressing challenges.