153: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos - Part 1

As the biotechnology sector races toward digital transformation, the buzz around Industry 4.0 - with its promise of interconnected systems, automation, and data-driven operations - has never been louder. But is the industry truly ready?

In this episode, we speak with Tiago Matos, Associate Principal Scientist/Associate Director in Bioprocess Drug Substance and Commercialization at Merck & Co., who brings a grounded, insider view. Despite the hype, he says most of biopharma is still operating at an “Industry 3.2” level.

With over a decade of experience in biologics and vaccines, Tiago leads teams pushing digital innovation forward - through tools like digital twins, advanced control strategies, and smart manufacturing platforms.

Key takeaways from this episode:

• Biotech is slowly transitioning toward true Industry 4.0, through collaboration and strategic leadership.
• Digital twins aren’t for everything. Focused use in platform processes yields the best return - broad implementation can be costly and complex.
• Regulators are ready. Far from being a barrier, they’re encouraging innovation and open to new ideas.

Curious to learn more? Check out the full blog post for deeper insights, and let us know your thoughts in the comments - how close do you think biomanufacturing is to a true digital revolution?

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:

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