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Reducing biopharmaceutical manufacturing costs through continuous processing in a flexible J.POD® facility
Fernando A Garcia1, Eva Gefroh1
1Just-Evotec Biologics, Inc., 401 Terry Avenue North, Seattle, WA 98109, USA.
Drug Discovery Today
|May 18, 2023
Summary
Process models reveal how biomanufacturing facility design impacts costs. Continuous bioprocessing offers a cost-effective strategy for producing high-quality biopharmaceuticals, even with fluctuating market demand.
Area of Science:
- Biopharmaceutical Manufacturing
- Process Systems Engineering
- Pharmaceutical Economics
Background:
- Biomanufacturing costs significantly influence commercial-scale production.
- Facility design and operational strategies must balance product demand with cost minimization.
- Traditional large-scale facilities face challenges in adapting to market fluctuations.
Purpose of the Study:
- To develop process models assessing the impact of biomanufacturing costs at commercial scale.
- To evaluate different facility design strategies, including traditional and portable-on-demand (POD) models.
- To compare bioprocessing platforms and illustrate the cost-effectiveness of continuous bioprocessing.
Main Methods:
- Scenario-based modeling approach to evaluate facility design strategies.
- Estimation of total production costs for various bioprocessing platforms across different facility types.
- Analysis of market demand fluctuations and their effect on manufacturing costs and plant utilization.
Main Results:
- Continuous bioprocessing emerged as a cost-effective approach for manufacturing high-quality biopharmaceuticals.
- Small-footprint, portable-on-demand (POD) facilities were evaluated against traditional large stainless-steel designs.
- Market demand variability significantly impacts manufacturing costs and plant utilization.
Conclusions:
- Facility design and operational choices are critical for minimizing biomanufacturing costs.
- Continuous bioprocessing presents a viable and economical solution for biopharmaceutical production.
- The total cost of biopharmaceuticals to patients is influenced by manufacturing economics and market dynamics.
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