Technology outlook for real‐time quality attribute and process parameter monitoring in biopharmaceutical development—A review
Abstract
Real‐time monitoring of bioprocesses by the integration of analytics at critical unit operations is one of the paramount necessities for quality by design manufacturing and real‐time release (RTR) of biopharmaceuticals. A well‐defined process analytical technology (PAT) roadmap enables the monitoring of critical process parameters and quality attributes at appropriate unit operations to develop an analytical paradigm that is capable of providing real‐time data. We believe a comprehensive PAT roadmap should entail not only integration of analytical tools into the bioprocess but also should address automated‐data piping, analysis, aggregation, visualization, and smart utility of data for advanced‐data analytics such as machine and deep learning for holistic process understanding. In this review, we discuss a broad spectrum of PAT technologies spanning from vibrational spectroscopy, multivariate data analysis, multiattribute chromatography, mass spectrometry, sensors, and automated‐sampling technologies. We also provide insights, based on our experience in clinical and commercial manufacturing, into data automation, data visualization, and smart utility of data for advanced‐analytics in PAT. This review is catered for a broad audience, including those new to the field to those well versed in applying these technologies. The article is also intended to give some insight into the strategies we have undertaken to implement PAT tools in biologics process development with the vision of realizing RTR testing in biomanufacturing and to meet regulatory expectations.
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Automated sampling systems such as MAST and Seg-Flow can draw samples from the bioprocess stream and deliver them to analytical devices for seamless analysis.
“Automated sampling systems such as MAST and Seg‐Flow can draw the samples from the bioprocess stream and deliver them to the analytical devices for ensuing seamless analysis [45, 46, 47].”
From Current PAT Landscape in the Downstream Processing of Biopharmaceuticals (2025) · cites this paper as [47]
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- Authors
- Wasalathanthri, D. P., Rehmann, M. S., Song, Y., Gu, Y., Mi, L., Shao, C., Chemmalil, L., Lee, J., Ghose, S., Borys, M. C., Ding, J., & Li, Z. J.
- Affiliations
- Bristol-Myers Squibb (United States) (US)
- Biologics Process Development Bristol‐Myers Squibb Company Devens Massachusetts
- Corresponding author
- Wasalathanthri, Dhanuka P.
- ORCID
- Venue
- Biotechnology and Bioengineering
- Publisher
- Wiley
- Published
- 2020-07
- Volume
- 117
- Issue
- 10
- Pages
- 3182-3198
- ISSN
- 0006-3592 (ISSN-L)
- 1097-0290
- OpenAlex
- W3035854730
- Semantic Scholar
- 1e25b6c93f3d47e557398cecd40a4478045e28ee
- Cited by
- 177
- References
- 93
- Citations by year
- 2026: 35 · 2025: 26 · 2024: 38 · 2023: 31 · 2022: 17 · 2021: 27 · 2020: 2
- FWCI
- 1.88
- Type
- journal article
- Language
- en
- Open access
- closed
- Locations
- Biotechnology and Bioengineering (publishedVersion)
- PubMed (publishedVersion)
- Topics
- Life Sciences › Biochemistry, Genetics and Molecular Biology › Molecular Biology › Viral Infectious Diseases and Gene Expression in Insects
- Physical Sciences › Engineering › Control and Systems Engineering › Fault Detection and Control Systems
- Life Sciences › Biochemistry, Genetics and Molecular Biology › Molecular Biology › Protein purification and stability
- Keywords
- process analytical technology, real-time monitoring, biopharmaceutical manufacturing, quality by design, real-time release testing, critical quality attributes, critical process parameters, data automation, data visualization, machine learning, deep learning, vibrational spectroscopy, multivariate analysis, mass spectrometry, sensors, automated sampling, regulatory compliance
- MeSH terms
- Biological Products, Quality Control, Technology, Pharmaceutical
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