Why are manufacturers shifting toward continuous bioprocess workflows?

Bioprocess technology has historically relied on batch processing, where large-volume tanks are filled, processed, and harvested in discrete intervals. However, the rise of specialized biologics and the need for cost reduction is driving a transition toward continuous bioprocessing. This technology allows for the constant addition of media and removal of waste, resulting in smaller footprints and higher product quality.

For strategic planners, this shift represents a move toward facility intensification. By running processes continuously, companies can achieve the same output in a 500L bioreactor that previously required a 5,000L vessel. This not only reduces capital expenditure (CAPEX) but also minimizes the risk of product degradation during lengthy hold times.

Is the adoption of Continuous Bioprocessing Equipment accelerating for Tier-1 Pharma?

Current data for 2024 suggests that Continuous Bioprocessing Equipment is now a top-three priority for global biopharmaceutical procurement teams. The ability to integrate upstream perfusion with downstream multi-column chromatography has proven to increase overall facility yield by up to 30%. This efficiency is critical as the industry faces increasing pressure from biosimilar competition and drug pricing regulations.

What is the outlook for 2024 and 2025?

Through 2025, the focus will move toward fully integrated "end-to-end" continuous lines. While upstream perfusion is relatively mature, downstream continuous purification remains a bottleneck. Technological advancements in automated buffer management and real-time viral clearance monitoring will be the key investment drivers in the next 18 months.

• Significant reduction in facility footprint and utility requirements.
• Enhanced product consistency through steady-state operation.
• Lower risk of catastrophic batch failure due to localized contamination.

Author: Sofiya Sanjay

Designation: Healthcare Research Consultant, Market Research Future

About: At Market Research Future (MRFR), we enable organizations to unravel complex industries through Cooked Research Reports (CRR), Half-Cooked Research Reports (HCRR), Raw Research Reports (3R), Continuous-Feed Research (CFR), and Market Research & Consulting Services. Our studies across products, technologies, applications, end users, and global to country-level segments help decision-makers see more, know more, and do more.

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