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The Future of BioManufacturing: Reduction in Market Scale Quantities

As novel types of Biologics have been developed, changes in biomanufacturing approaches have been running in parallel with the intention of maximising yield and lowering production costs. Evolution Global have identified 8 key production trends that will shape the Future of BioManufacturing, the third of which is Reductions in Market Scale Quantities.

INTRODUCTION

Many novel treatments are being targeted towards orphan indications and/or conditions which offer a personalised medicine approach, resulting in a reduction in the manufacturing scale required. Evolution Global’s analysis focuses on regional scale as it pertains to types of treatment that are currently in development in active, industry-funded clinical trials across the world.

REGIONAL FOCUS: THE RISE OF THE EAST

We are amid a paradigm shift in regional centricity as it pertains to biopharmaceutical clinical development. Historically North America (USA & Canada) followed by Europe have been the powerhouse regions of Biopharmaceutical Development and Manufacture. As an increasing number of Phase 1/2 developments enter from China, the APAC region will soon overtake Europe in terms of initial developments that will translate to later stage developments and eventually products. With regards to active industry-funded biopharmaceutical clinical trials as of the end of June 2017, the current global situation can be summarised as follows:

Of note is the fact that active early-stage trials (Phase 1/2) in China/South Korea/Taiwan are now comparable to ongoing developments in Europe. The compound annualised growth rate (CAGR) in early-stage trials highlights the rise over the last 10 years:

TREATMENT FOCUS: THE RISE OF CELL THERAPY

Running in parallel with the regional shift are changes in the categories of biologics themselves. It is likely that novel Monoclonal Antibodies, Vaccines and Peptides will continue to hold a predominant position. Assuming comparable clinical trial attrition rates, there will be a rise in Cell Therapy approaches for both Cancer and Regenerative Medicine.

Of the note is the potential rise in autologous-based cell therapies, which may account for approximately 10% of total Biopharmaceutical production within the next 7 to 10 years.

SCALES BY THERAPEUTIC CATEGORY

From a manufacturing point of view, it is likely that market scale options will expand to include greater utilisation of Single-Use Disposables at the 2L volume which, if optimised, can offer a 5-fold reduction in volume with same output when compared to stainless steel vessels. For Allogeneic Regenerative Medicines, Cancer Immunotherapies and Gene Therapies, disposable 2L scale is likely to be the primary format utilised going forward. The choice of DSP mode (Downstream Processing) is likely to have a significant influence, with viable options such as Batch, semi-continuous and continuous requiring consideration. Scales for Autologous Regenerative Medicines and Cancer Immunotherapies would be much smaller.

Category% of Total in 7 to 10 yearsManufacturing Options
Allogeneic Cancer Immunotherapy3% to 13%Disposable 2L Scale; Options: Continuous, Semi-Continuous
Allogeneic Regenerative Medicine5% to 7%Disposable 2L Scale; Options: Continuous, Semi-Continuous
Autologous Cancer Immunotherapy5% - 8%Disposable < 500ml; Continuous
Autologous Regenerative Medicine2% - 4%Disposable < 500ml; Continuous
Biobetter Peptides/Proteins (Incl. Fusion)2% - 5%%Stainless Steel > 10L, Batch to Batch, Continuous or Disposable 2L Scale; Options: Continuous, Semi-Continuous
Biosimilar Antibody6%-8%Stainless Steel > 10L, Batch to Batch, Continuous or Disposable 2L; Scale Options: Continuous, Semi-Continuous
Biosimilar Peptides/Proteins (Incl. Fusion)2% - 5%Stainless Steel > 10L, Batch to Batch, Continuous or Disposable 2L Scale; Options: Continuous, Semi-Continuous
Gene Therapy2% - 4%Disposable 2L Scale; Options: Continuous, Semi-Continuous
Improved Plasma IG2% - 5%Traditional
Novel Peptides/Proteins (Incl. Fusion)8% - 11%Stainless Steel > 10L; DSP Options: Batch, Continuous or Disposable 2L Scale; Options: Continuous, Semi-Continuous
Novel Monoclonal Antibodies (Incl. ADC & Bispecific)20% to 24%Stainless Steel > 10L, Batch to Batch, Continuous or Disposable 2L Scale; Options: Continuous, Semi-Continuous
Vaccine (Infectious Disease)7% - 14%Traditional; or if Viral based, Disposable 2L Scale; DSP Options: Continuous, Semi-Continuous

CONCLUSION

Going forward, there is no doubt that biopharmaceutical manufacturing scales will change to smaller scales that offer outputs similar to larger volume stainless steel vessels. Additionally the sector will experience a regional paradigm shift, with China replacing Europe as the second most important geographic region for manufacture overall.

Check back with Evolution Global in mid-August when we publish our in-depth analysis of the fourth key production trend in our “Future of BioManufacturing” series, which will focus on Perfusion Culture.

Evolution are global executive & commercial search specialists for the BioPharma Industry.

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