154: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos - Part 2

In this episode, Tiago Matos, Associate Principal Scientist/Associate Director in Bioprocess Drug Substance and Commercialization at Merck & Co., shares a critical insight: continuous manufacturing in biologics currently demands 2–3x more time and FTEs than traditional fed-batch approaches. This highlights both the complexity of the shift - and the urgency for smarter digital tools and cross-functional collaboration.

With over a decade of experience and a strong track record in biologics and smart manufacturing, Tiago brings a balanced view of the promise and practical challenges of digital transformation in bioprocessing.

Top 3 Takeaways:

• Continuous Manufacturing is Coming - But Slowly: The infrastructure and tools aren’t fully ready. Progress depends on better-integrated solutions and stronger collaboration across industry, equipment providers, and regulators.
• Collaboration is Key: No one drives transformation alone. Digital, automation, modeling, and process experts must work together - like building a functional protein from diverse amino acids.
• Digital Twins and AI Will Bridge the Gap: AI, soft sensors, and digital twins will help streamline control strategies. The goal isn’t perfect models, but reliable, adaptive systems that improve in real time.

Tiago’s vision is both realistic and inspiring: the future of biologics manufacturing lies in openness, teamwork, and continuous learning.

What challenges or questions do you face in the shift to digital bioprocessing?

Here is what other guests had to say on this topic:

• Episodes 5-6: Hybrid Modeling: The Key to Smarter Bioprocessing with Michael Sokolov;
• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli;
• Episodes 121-122: The Transformative World of Digital Solutions in Bioprocessing with Simon Wieninger.

Connect with Tiago Matos:

LinkedIn: www.linkedin.com/in/tiagobmatos

Merck & Co.: www.merck.com

Next step:

Transform your bioprocess development strategy with a complimentary consultation. Schedule your expert session: https://bruehlmann-consulting.com/call

Ready to scale up? Join our exclusive 1:1 Strategy Call and learn proven methods to reduce development and manufacturing costs while maintaining product quality. Our bioprocess experts will help you navigate complex bioprocessing challenges and regulatory requirements. Limited spots available: https://stan.store/SmartBiotech

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