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Comparison between Batch and Continuous Monoclonal Antibody Production and Economic Analysis

Yang, Ou, Prabhu, Siddharth, Ierapetritou, Marianthi
Industrial & engineering chemistry process design and development 2019 v.58 no.15 pp. 5851-5863
antibody formation, biopharmaceuticals, cost effectiveness, manufacturing, monoclonal antibodies, process design, tanks
This work aims to evaluate the benefits of the continuous process in biopharmaceutical manufacturing of monoclonal antibodies (mAbs). An integrated continuous process is designed and built using a process simulator and compared with a fed-batch process production line. The comparisons are based on cost of goods (COG/g) calculation and sensitivity analysis. The fed-batch process results in operating COG/g of $99/g in mAbs production, whereas the continuous process accounts for $51/g. Because of the smaller footprint and fewer storage tanks required in the continuous process, the facility cost reduced by 66%, compared to the fed-batch process. In continuous production, there is a better utilization of the primary capture resin, which leads to a reduction in consumables cost by 68%. Sensitivity analysis is used to evaluate the process in different manufacturing scales (50–1200 kg/yr), upstream titers (1.5–5.5 g/L), and downstream yield (70%–80%). Cost savings can be observed through the entire range.