Applied Advanced Process Analytics in Biopharmaceutical Manufacturing: Challenges and Prospects in Real-time Monitoring and Control

Cenk Undey,  Sinem Ertunc,  Thomas Mistretta,  Manuj Pathak
Amgen, Inc.


Abstract

Biopharmaceutical manufacturing processes are inherently complex due to their nonlinear bioprocess dynamics, variability in batch operations and manufacturing schedule, raw materials involved, and automatic process control. A typical processed lot generates large amounts of data that need to be analyzed and interpreted for process troubleshooting and continuous improvement support purposes in addition to product release. Multivariate Batch Process Modeling, Monitoring and Control approaches in real-time will be elaborated by providing industrial examples from the commercial manufacturing processes. Examples and opportunities in cell culture (e.g., bioreactor applications) and purification (e.g., large-scale chromatography) operations are summarized. Impact of Process Analytical Technologies, soft-sensor development, first principles modeling applications and commercial-scale examples will be presented.