Innovative Tech for Drug Manufacturing: Revolutionizing Pharma

October 31, 2023 - The pharmaceutical industry is no stranger to technological innovation. Over the years, it has seen numerous advancements in drug development, manufacturing processes, and quality control. However, in recent years, the pace of innovation in drug manufacturing has accelerated dramatically.

Continuous Manufacturing

Traditionally, pharmaceutical manufacturing has followed a batch-based approach, which involves producing drugs in large, discrete batches. However, the industry is increasingly moving toward continuous manufacturing, a more agile and efficient method. Continuous manufacturing streamlines production, reduces waste, and enhances quality control. It also allows for quicker response to market demands and reduces the need for extensive warehouse storage.

Continuous manufacturing has demonstrated commercial viability with companies such as Pfizer, Eli Lilly, GSK, and others, resulting in the approval of more than half a dozen medicines created by continuous manufacturing in the US.

3D Printing

3D printing technology has made significant inroads in the pharmaceutical sector. It is used for personalized drug formulations, medical device manufacturing, and drug delivery systems. By enabling the production of complex drug structures with precision, 3D printing has the potential to revolutionize drug manufacturing and customization.

In 2015, Aprecia Pharmaceuticals pioneered the first FDA-approved 3D-printed medication, SPRITAM, designed for rapid dissolution in water, facilitating ingestion for patients with swallowing difficulties. SPRITAM is intended for the management of partial onset seizures, myoclonic seizures, and primary generalized tonic-clonic seizures. This accomplishment results from Aprecia's innovative 3D printing technology, known as ZipDose Technology, enabling the tablet to disintegrate in the mouth with minimal water, highlighting the potential of 3D printing in enhancing both pharmaceutical manufacturing and patient adherence.

Artificial Intelligence (AI) and Machine Learning (ML)

AI and ML are changing the game in drug manufacturing. These technologies are used for process optimization, predictive maintenance, and quality control. AI-driven algorithms can analyze vast datasets and identify patterns humans might miss, improving efficiency and reducing costs.

In 2019, Insilico Medicine demonstrated the power of AI by creating a molecule targeting a fibrosis-related protein in just 46 days. Since then, they've reached Phase II clinical trials for INS018_055, an AI-discovered anti-fibrotic drug, following Phase 0 and Phase I success. This milestone highlights AI's potential to expedite drug development, addressing unmet medical needs in record time.

Internet of Things (IoT) and Smart Manufacturing

IoT has found its way into the pharmaceutical industry, connecting machines, sensors, and devices to improve manufacturing processes. Smart manufacturing relies on real-time data and analytics to monitor and control production, ensuring product consistency and quality.

For example, many pharmaceutical companies, such as Pfizer, AstraZeneca, GSK, Novartis, Roche, Johnson & Jonhson, Merck, Sanofi, Eli Lilly, and AbbVie, have incorporated IoT devices and real-time data analytics in their manufacturing facilities to ensure precise control over the production process, enhance product quality, and streamline operations.

Advanced Analytics and Big Data

The pharmaceutical industry generates vast data during research, development, and manufacturing. Advanced analytics and big data technologies are now being used to extract valuable insights from this data, improving decision-making and production efficiency.

In collaboration with Accenture, Biogen has harnessed quantum computing to expedite the drug discovery process. They adopted a structural molecular comparison algorithm with the assistance of 1QBit, and the breakthrough showed that quantum computing could potentially enhance pharmaceutical industry drug discovery by enabling the comparison of larger molecules, ultimately leading to advancements and potential cures for various diseases.

Robotic Process Automation (RPA)

Robotic process automation has been integrated into drug manufacturing to enhance speed and precision in various aspects of the production process. Robots are utilized for tasks like dispensing, labeling, and packaging, reducing the potential for human error and increasing production efficiency.

In 2020, Eli Lilly and Company and Strateos, Inc. introduced the Lilly Life Sciences Studio lab in San Diego, a state-of-the-art robotic laboratory designed to accelerate drug discovery. This lab integrates various aspects of drug discovery, such as design, synthesis, purification, and analysis, into a fully automated platform, accessible through Strateos' cloud-based platform. Researchers can control experiments remotely, promoting real-time reproducible experiments, and the partnership aims to expand access to the lab's technology for the scientific community.

Blockchain for Supply Chain Transparency

Ensuring the authenticity and integrity of pharmaceutical products throughout the supply chain is a critical concern. Blockchain technology has emerged as a solution to enhance transparency, traceability, and security in the pharmaceutical supply chain.

In 2019, IBM, KPMG, Merck, and Walmart teamed up for an FDA pilot program that aims to use blockchain to enhance the traceability and security of prescription drugs in the US. The project was intended to create a shared blockchain network that allows real-time monitoring of products, reducing tracking times and ensuring product integrity in the supply chain.

Virtual Reality (VR) and Augmented Reality (AR)

VR and AR technologies are entering pharmaceutical manufacturing for training, design, and quality control. These immersive technologies provide a more interactive and intuitive approach to complex tasks.

GSK has incorporated VR and AR into its pharmaceutical manufacturing facilities for training. Employees can undergo virtual training exercises, improving their skills and efficiency in a controlled, immersive environment.

Gene and Cell Therapy Manufacturing

The gene and cell therapies field presents manufacturing challenges and opportunities distinct from traditional pharmaceuticals. These therapies often involve highly specialized processes, such as modifying and manipulating a patient's cells to create personalized treatments. To meet the increasing demand and ensure the success of these therapies, the biopharma industry is turning to innovative manufacturing technologies.

For instance, Yescarta, a CAR-T cell therapy, involves genetically modifying a patient's T cells to target and destroy cancer cells. Gilead's expansion of its Amsterdam facility to produce Yescarta for 4,000 patients annually exemplifies the crucial role of advanced manufacturing infrastructure in efficiently delivering these cutting-edge therapies to patients.

As the industry continues to evolve, it's clear that staying at the forefront of technological innovation is essential for pharmaceutical companies to remain competitive and deliver high-quality, personalized treatments to patients worldwide. Embracing these innovative technologies is a smart business move and a commitment to improving the health and well-being of people worldwide.