Iterative modeling and optimization of biomass production using experimental feedback

Current challenges and recent advances on the path towards continuous biomanufacturing

Continuous biopharmaceutical manufacturing is currently a field of intense research due to its potential to make the entire production process more optimal for the modern, ever-evolving biopharmaceutical market. Compared to traditional batch manufacturing, continuous bioprocessing is more efficient, adjustable, and sustainable and has reduced capital costs. However, despite its clear advantages, continuous bioprocessing is yet to be widely adopted in commercial manufacturing. This article provides an overview of the technological roadblocks for extensive adoptions and points out the recent advances that could help overcome them. In total, three key areas for improvement are identified: Quality by Design (QbD) implementation, integration of upstream and downstream technologies, and data and knowledge management. First, the challenges to QbD implementation are explored. Specifically, process control, process analytical technology (PAT), critical process parameter (CPP) identification, and mathematical models for bioprocess control and design are recognized as crucial for successful QbD realizations. Next, the difficulties of end-to-end process integration are examined, with a particular emphasis on downstream processing. Finally, the problem of data and knowledge management and its potential solutions are outlined where ontologies and data standards are pointed out as key drivers of progress.

Modelling and mathematical optimisation of wastewater treatment in food industries

The current paper describes the work carried out in the Horizon 2020 AFTERLIFE project -  "Advanced Filtration TEchnologies for the Recovery and Later conversIon of relevant Fractions from wastEwater" - (Grant Agreement no. 745737) which focuses on bioprocess modelling and optimisation using computational tools. The project addresses the development of a flexible, cost- and resource-efficient process framed in the zero-waste and circular economy approach for the recovery and valorisation of the relevant fractions from wastewater. The first step of such a process is an initial step consisting of a cascade of membrane filtration units to separate the total solids in sewage. Then, the concentrates recovered in each unit will be treated to obtain high-pure extracts and metabolites or to be converted into value-added biopolymers (polyhydroxyalkanoates). Moreover, the outflow of the process is an ultra-pure water stream that can be directly reused. Following a holistic approach, the design and optimisation of the AFTERLIFE process will improve performance and reduce the costs associated with wastewater treatment by maximising the value recovery. The paper focuses on the work done developing and implementing computational tools to model and optimise the design of the process. A framework for modelling-based optimisation has been developed. The applied optimisation approach is not computationally demanding and can be systematically applied to different processes. Finally, a use case establishing a scenario for testing the developed framework is described. The defined process model and optimisation methodology were applied to simulate the treatment of wastewater from the fish processing industry. The performance of the optimisation tool is analysed considering the simulation results.

History and Evolution of Modeling in Biotechnology: Modeling & Simulation, Application and Hardware Performance

Biological systems are typically composed of highly interconnected subunits and possess an inherent complexity that make monitoring, control and optimization of a bioprocess a challenging task. Today a toolset of modeling techniques can provide guidance in understanding complexity and in meeting those challenges. Over the last four decades, computational performance increased exponentially. This increase in hardware capacity allowed ever more detailed and computationally intensive models approaching a "one-to-one" representation of the biological reality. Fueled by governmental guidelines like the PAT initiative of the FDA, novel soft sensors and techniques were developed in the past to ensure product quality and provide data in real time. The estimation of current process state and prediction of future process course eventually enabled dynamic process control. In this review, past, present and envisioned future of models in biotechnology are compared and discussed with regard to application in process monitoring, control and optimization. In addition, hardware requirements and availability to fit the needs of increasingly more complex models are summarized. The major techniques and diverse approaches of modeling in industrial biotechnology are compared, and current as well as future trends and perspectives are outlined.

Digital Twins in Pharmaceutical and Biopharmaceutical Manufacturing: A Literature Review

The development and application of emerging technologies of Industry 4.0 enable the realization of digital twins (DT), which facilitates the transformation of the manufacturing sector to a more agile and intelligent one. DTs are virtual constructs of physical systems that mirror the behavior and dynamics of such physical systems. A fully developed DT consists of physical components, virtual components, and information communications between the two. Integrated DTs are being applied in various processes and product industries. Although the pharmaceutical industry has evolved recently to adopt Quality-by-Design (QbD) initiatives and is undergoing a paradigm shift of digitalization to embrace Industry 4.0, there has not been a full DT application in pharmaceutical manufacturing. Therefore, there is a critical need to examine the progress of the pharmaceutical industry towards implementing DT solutions. The aim of this narrative literature review is to give an overview of the current status of DT development and its application in pharmaceutical and biopharmaceutical manufacturing. State-of-the-art Process Analytical Technology (PAT) developments, process modeling approaches, and data integration studies are reviewed. Challenges and opportunities for future research in this field are also discussed.