Smart Biotech Scientist | Master Bioprocess CMC Development, Biologics Manufacturing & Scale-up, Cell Culture Innovation 192: Process Intensification Secrets: A Process Engineer's Decision Framework with Andreas Castan - Part 2
Sep 25, 2025
Andreas Castan, a seasoned expert in bioprocessing at Cytiva, explores the nuances of continuous manufacturing. He challenges the notion that continuous processes automatically deliver productivity gains, revealing that operational complexities and media costs can offset savings. Regulatory hurdles remain despite FDA backing, stressing the need for strong QA measures. Andreas emphasizes strategic timing for adopting continuous methods and warns against blindly embracing technology. He advocates for tailored solutions, focusing on robustness and understanding production bottlenecks.
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Perfusion Greatly Raises Upstream Productivity
- High-density perfusion can boost productivity 3–5x versus fed-batch, letting you use much smaller bioreactors.
- Smaller reactors cut capital and HVAC needs but add operational and integration complexity.
Industry Uses Mixed Adoption Strategies
- Some large pharma (AstraZeneca, Sanofi, Merck) pursue full continuous manufacturing driven by pipeline needs.
- Other firms use hybrid models like perfusion plus multicolumn chromatography or intensified N-1 perfusion for titer gains.
Choose Technology Based On Business Case
- Treat choice of continuous versus intensified fed-batch as a strategic business decision tied to pipeline and volumes.
- Keep the solution as simple as possible and match it to organizational capabilities.