BIO 2025 Boston - The "What do we expect to see" series - 2. Next Generation Biomanufacturing
BIO 2025: Next-Generation Biomanufacturing – Scaling Innovation for a Sustainable Future BIO 2025, taking place June 16–19 at the Boston Convention & Exhibition Center, will bring together over 20,000 leaders across biotechnology, pharma, and manufacturing. Among the standout topics is next-generation biomanufacturing, with dedicated sessions examining how advances in automation, continuous processing, and AI integration are revolutionising biologics production. The Biomanufacturing & Bioprocessing track features insights into improving efficiency, agility, and sustainability across the development and scale-up of therapies.
Key Biomanufacturing Sessions at BIO 2025
1. Biomanufacturing 4.0 – Building Smart, Flexible Facilities Session ID: BM-407B | Date: June 17, 2025 This panel, moderated by Deloitte, will explore how digital twins, process analytical technologies (PAT), and real-time release testing (RTRT) are enabling adaptive, efficient facilities. Speakers from GSK, Resilience, and Cytiva will discuss:
Alex’s view: At CPI, we are actively advancing Biomanufacturing 4.0 through our Digital Grand Challenge initiatives. In Grand Challenge 1, we've developed a digitally twinned continuous direct compression (CDC) platform, integrating advanced PAT systems to enable real-time monitoring and control of oral solid dosage manufacturing processes. This integration allows for enhanced process understanding, reduced material waste, and improved product quality. Similarly, Grand Challenge 2 focuses on automating clinical trial supply chains, where we've implemented PAT tools within our Pharmacy Automation for Clinical Efficiency (PACE) platform to facilitate just-in-time manufacturing and real-time quality assurance. These efforts exemplify our commitment to creating smart, flexible manufacturing facilities that leverage digital technologies to enhance efficiency and adaptability in biologics production. (Applied SmartFactory Solutions, The Medicine Maker)
2. The Biologics Scale-Up Challenge – From Bench to GMP Session ID: BM-418C | Date: June 18, 2025 Moderated by Bioprocess International, this session features leaders from Moderna, Lonza, and FUJIFILM Diosynth, who will examine:
Alex’s view: Biologics scale-up remains a critical bottleneck for innovative therapies, particularly mRNA, cell, and gene therapies. While early-stage development is becoming faster, GMP readiness often lags, limiting the pace of commercialisation. Modular and single-use systems are easing this transition by offering flexible, lower-capex options with faster turnaround—ideal for multi-product facilities or decentralised manufacturing models.
At CPI, we specialise in bridging this gap. Our facilities support the development and scale-up of a wide range of biologics, including mRNA vaccines, monoclonal antibodies, VLPs, recombinant proteins, viral vectors, and live biotherapeutic products. We provide end-to-end solutions, from upstream and downstream process development to analytical characterisation and fill-finish services. Our experience with both microbial and mammalian systems enables us to tailor processes to the specific needs of each product, ensuring efficient and scalable manufacturing pathways.(CPI)
Tech transfer continues to be a pain point, with inconsistencies in documentation, material quality, and process understanding across partners. Platform-based approaches and digital process maps can help standardise and de-risk this handover. Meanwhile, demand for skilled bioprocess engineers and digitally fluent technicians is increasing, highlighting the need for workforce investment alongside technological upgrades.
3. Decarbonising Biopharma – Sustainable Manufacturing Strategies Session ID: BM-435A | Date: June 19, 2025 Led by the World Economic Forum and co-hosted by Genentech and Sartorius, this session dives into:
Alex’s view: The biopharma industry is under growing pressure to cut carbon emissions while maintaining production efficiency and product quality. Sustainability is no longer a “nice-to-have”—it’s a regulatory and reputational imperative. Companies are beginning to move beyond carbon offsets toward decarbonising operations themselves, especially in energy-intensive biologics manufacturing.
At CPI, sustainability is integral to our operations. We employ process intensification and continuous processing techniques to enhance efficiency and reduce environmental impact. Our Grand Challenge 3 initiative focuses on developing sustainable, scalable, and cost-effective manufacturing processes for oligonucleotide-based medicines. This includes exploring liquid-phase synthesis and biocatalysis to minimise solvent use and waste generation, thereby lowering the carbon footprint of oligonucleotide production.
Furthermore, CPI is extending its sustainability efforts internationally. In India, we've launched the Living Lab Project in collaboration with CSIR-National Chemical Laboratory (CSIR-NCL) to decarbonise the pharmaceutical industry. This initiative focuses on adopting green manufacturing practices, such as continuous flow chemistry and mechanochemistry, to reduce solvent use and improve efficiency. By addressing Scope 1, 2, and 3 emissions, the project aims to create a more sustainable pharmaceutical supply chain, aligning with global environmental standards. (LinkedIn)
CPI at BIO 2025 CPI will engage with attendees to support sustainable biomanufacturing, advanced biologics scale-up, and digital transformation in GMP environments. Reach out to me (alex.cole@uk-cpi.com) to arrange a conversation on how we can collaborate to accelerate sustainable innovation in your development pipeline.
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All session details sourced from the official BIO 2025 programme.