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The world of biologics manufacturing is undergoing a major transformation. Once dominated by traditional batch processes, the industry is now experiencing a marked shift toward continuous bioprocessing.

But as companies contemplate this transition, two questions dominate strategic discussions: Will regulators accept continuous manufacturing? And, perhaps more pressingly, Does the business case justify making the switch?

In this podcast episode of the Smart Biotech Scientist Podcast, David Brühlmann dives into these pivotal topics - drawing insights from real-world case studies, regulatory updates, and economic analyses.

Top three takeaways:

• Regulators Are On Board: The FDA, EMA, and global agencies now actively support continuous processing when robust controls and monitoring are in place.
• Real Economic Wins: Cost of goods reductions of up to 35% are possible at certain production scales, with much smaller facilities and lower risk of batch failure.
• Hybrid & Phased Approaches Work: Companies are finding success by first investing in enabling technologies and gradually transitioning, rather than making sudden changes.

Continuous bioprocessing is no longer an experimental promise - it’s an evolving standard. With regulatory bodies championing the shift, real-world implementations proving technical and economic viability, and strong financial incentives for the right manufacturers, the transition becomes not a question of “if,” but “when.”

Curious how continuous manufacturing can fit into your strategy? Listen to this episode and share your thoughts or questions!

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

Send us a text

In this episode of the Smart Biotech Scientist Podcast, host David Brühlmann dives into continuous bioprocessing - a major shift in biologics manufacturing that's turning traditional batch processes into streamlined, real-time operations.

Imagine running your biologics process non-stop for 30 days, with smart monitoring and smaller, more efficient systems replacing massive reactors. It’s not just possible - it’s already happening across the industry, from Amgen’s 80% smaller facility to Sanofi’s modular "Factory of the Future."

David explores how companies - big and small - are increasing productivity, cutting costs, and reducing waste through continuous strategies. You'll also hear about enabling technologies, phased implementation approaches, and the challenges teams are navigating as they make the shift.

Top 3 Takeaways:

• Efficiency & Cost Savings Are Real: Amgen’s results speak volumes: 80% smaller footprint, faster deployment, and cost reductions of over 60% per gram of protein.
• It’s Not Just for Big Pharma: Small and mid-sized biotechs are embracing continuous processes to stay competitive - gaining speed, flexibility, and lowering production costs without massive infrastructure.
• You Don’t Have to Go All In: Challenges like cost, complexity, and workforce readiness exist - but many companies are succeeding with hybrid models, applying continuous techniques step-by-step.

What’s your take on continuous manufacturing? Tune in, share your thoughts, and join the conversation about the future of biotech production.

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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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

Send us a text

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:

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

Send us a text

Is an Indian CDMO the right move for your biologics CMC development?

Pulling back the curtain on what might be your next strategic manufacturing advantage, this episode reveals the hidden capabilities emerging from India that leading biotech companies are racing to access. As supply chain vulnerabilities continue to expose risks in traditional manufacturing models, could the solution lie halfway around the world?

Joining us to reveal the inside story is Abdelaziz Toumi, CEO of Lupin Manufacturing Solutions and veteran of global pharma giants like Bayer, Merck and Lonza. With over 20 years in biotech, Abdelaziz brings unique insights on when and why you might want to look beyond traditional Western manufacturing partners. Our host, David Brühlmann, leverages his 15+ years of biotech industry experience to extract the practical insights you need to make informed decisions about your manufacturing strategy.

In this second segment, we'll dive deeper into the Indian CDMO and biomanufacturing landscape. Then we'll explore Lupin's specialized capabilities and finally extract Abdelaziz's most valuable leadership insight from his role as a CEO.

Key insights from this episode:

• The One-Stop Solution Advantage: Discover how Lupin is building rare end-to-end manufacturing capabilities for complex modalities like Antibody-Drug Conjugates (ADCs) - potentially eliminating the headache of managing multiple manufacturing partners across continents.
• Beyond Labor Cost Advantages: "Digitalization plays a key role, especially if you are operating in a cost-competitive space," explains Abdelaziz. Learn how Indian CDMOs are strategically automating key processes to drive both efficiency and quality, challenging Western perceptions.
• Leadership Across Cultures: "Listen, listen, listen," emphasizes Abdelaziz when discussing cross-cultural leadership. Understand the subtle communication dynamics that can make or break a global manufacturing partnership, especially when navigating hierarchy-sensitive cultures.

Whether you're actively evaluating Indian manufacturing options or simply preparing for the shifting global biotech landscape, these next several minutes deliver insights you can't afford to miss.

Listen to the full episode to extract the specific capability indicators that will help you determine if and when an Indian CDMO partnership makes strategic sense for your unique biologics pipeline.

Want to find out more about the CDMO selection? Here’s what one of our distinguished guests had to say about it:

• Episodes 103-104: One-Stop Shop vs. Specialist CDMO: A Scientist's Guide to CDMO Selection with Sigma Mostafa

Connect with Abdelaziz Toumi:

LinkedIn: www.linkedin.com/in/abdelaziztoumi

Lupin Manufacturing Solutions: www.lupin.com

Next step:

Transform your process 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

Send us a text

Is an Indian CDMO the right move for your biologics pipeline?

As Western biotech companies seek new strategic advantages, one question keeps surfacing: Is India truly becoming the next biotech manufacturing powerhouse? And what hidden capabilities are emerging that leading companies are racing to access?

In this episode of the Smart Biotech Scientist Podcast, Abdelaziz Toumi, CEO of Lupin Manufacturing Solutions and veteran of global pharma giants like Bayer, Merck, and Lonza, joins host David Brühlmann to reveal the inside story on when and why you might want to look beyond traditional Western manufacturing partners.

Here are three key insights from their conversation:

• The Post-Pandemic Manufacturing Revelation: "During the pandemic, we realized how vulnerable our supply chain truly is," explains Abdelaziz. Discover why diversifying manufacturing partnerships isn't just smart—it's becoming essential for resilience in an unpredictable world.
• Beyond the Cost Advantage: While Indian CDMOs can deliver up to 80% cost savings compared to Western counterparts, Abdelaziz reveals the unexpected advantages that make the most strategic partnerships about far more than budget considerations.
• The Trust Factor: "This is a business of trust," emphasizes Abdelaziz. Learn the critical questions that separate world-class Indian CDMOs from the rest, and the cultural nuances that can make or break your manufacturing partnership.

Ready to discover if Indian CDMOs could be the missing piece in your biologics development strategy? Tune in for expert insights on IP protection, talent access, and how to navigate the cultural dynamics that determine success in this emerging manufacturing powerhouse.

Listen to the full episode to unlock the strategic advantage that could transform your pipeline's journey from lab to market.

Want to find out more about the CDMO selection? Here’s what one of our distinguished guests had to say about it:

• Episodes 103-104: One-Stop Shop vs. Specialist CDMO: A Scientist's Guide to CDMO Selection with Sigma Mostafa

Connect with Abdelaziz Toumi:

LinkedIn: www.linkedin.com/in/abdelaziztoumi

Lupin Manufacturing Solutions: www.lupin.com

Next step:

Transform your process 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

Send us a text

As biotech labs rush to adopt AI tools for cell culture media development, a critical question emerges: Are we creating a generation of scientists who know which buttons to push but not why they're pushing them? The automation trap that once transformed laboratory workflows now threatens to fundamentally alter how we understand the complex dynamics of culture media composition and performance.

In this second part of our conversation with Tom Fletcher, R&D Director at Fujifilm Irvine Scientific, host David Brühlmann explores the practical challenges of implementing AI in cell culture media development while preserving the scientific thinking that drives true innovation.

Key Insights from Their Conversation:

• The Knowledge Generation Imperative: "Don't just think of your job as picking winners out of random experiments," Tom warns. He emphasizes that scientists must prioritize understanding why a specific media formulation works, not just that it works—a distinction that becomes critical as AI makes high-throughput media screening increasingly accessible.
• Bridging Disciplinary Divides: As teams become more diverse—incorporating data scientists, automation specialists, and traditional bioprocess experts—success depends on creating a collaborative culture where specialists learn to leverage each other's strengths without expecting everyone to have the same foundation in cell culture fundamentals.
• The Future Bioprocessing Landscape: Tom predicts that while platform media will dominate for speed to clinic, human roles will evolve toward managing automated, digitalized processes with fewer but more technically specialized staff. The media developers who thrive will be those who can maintain scientific rigor while harnessing the power of automation.

For biotech leaders navigating this technological transition, Tom's advice is clear: "Embrace AI because I think we all believe it's valuable, but don't allow lazy science to creep in... if you don't resist it, people are going to get lazy and just say 'I've got this supercomputer and I know which buttons to push.' That's not good enough."

If you enjoyed this conversation, be sure to explore how it all began:

• Episodes 1-2: Unlock the Power of Rational Media Design in Bioprocessing with Tom Fletcher

Connect with Tom Fletcher:

LinkedIn: www.linkedin.com/in/tomfletcher2

FUJIFILM Irvine Scientific: www.irvinesci.com

The views and opinions expressed by Tom Fletcher are his own and do not necessarily reflect those of Fujifilm Irvine Scientific or its affiliates.

Next step:

Transform your cell culture media 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

Note: These are Tom’s personal opinions and not his company’s.

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From closely-guarded secrets to complex chemical interactions, cell culture media development has transformed from an afterthought to a critical competitive advantage in modern bioprocessing. But as AI and automation revolutionize the field, are we at risk of gaining speed while losing understanding?

In this eye-opening episode of the Smart Biotech Scientist Podcast, host David Brühlmann speaks with Tom Fletcher, R&D Director at Fujifilm Irvine Scientific, who brings over 30 years of experience and a unique perspective on balancing technological innovation with scientific rigor.

Key Insights from Their Conversation:

• The Evolution of Media Formulations: Tom traces the remarkable journey from basic serum supplements to today's chemically defined media with 60-70+ precisely balanced components, transforming what was once "just that stuff you bought" into one of bioprocessing's most closely guarded competitive advantages.
• The Collaborative Intelligence Framework: The most powerful approach combines artificial intelligence with human intelligence (AI + HI = CI), where technology enhances rather than replaces scientific thinking to generate not just data, but genuine process understanding.
• Avoiding the Automation Trap: "Don't get lazy with technology," Tom warns, emphasizing that the goal remains generating knowledge about why processes work, not just identifying which conditions perform best—a crucial mindset as companies increasingly adopt powerful AI tools.

If you enjoyed this conversation, be sure to explore how it all began:

• Episodes 1-2: Unlock the Power of Rational Media Design in Bioprocessing with Tom Fletcher

Connect with Tom Fletcher:

LinkedIn: www.linkedin.com/in/tomfletcher2

FUJIFILM Irvine Scientific: www.irvinesci.com

The views and opinions expressed by Tom Fletcher are his own and do not necessarily reflect those of Fujifilm Irvine Scientific or its affiliates.

Next step:

Transform your cell culture media 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