CRB has released its highly anticipated 2024 Horizons: Life Sciences report, packed with invaluable insights into the emerging trends that are reshaping research and manufacturing facilities in the life sciences sector. As a leading full-service firm in facility design, engineering, construction, and consulting for both life sciences and food & beverage industries, CRB is recognized for its commitment to innovative, sustainable solutions. With a presence in 20 offices across the U.S., Canada, and Europe.
This year’s report, based on a survey of 500 industry leaders—including therapeutic developers and CDMO executives—features insights from companies of all sizes: large (10,000+ employees), medium (500–9,999 employees), and small (fewer than 500 employees). It spans a wide range of technologies, from traditional biologics to cutting-edge cell and gene therapies. Unlike previous editions that focused on individual therapies, this report takes a comprehensive view of facility design, encompassing digital trends, laboratory setups, and drug production, establishing a benchmark for the industry.
Peter Walters, Fellow and Advanced Therapies expert at CRB, highlighted the report’s evolution, stating, “This report captures the rapid advancements in technology and manufacturing across the life sciences. Facility design and construction must adapt to these changes, particularly with the rise of personalized medicine and biologics.”
He emphasized the need for more flexible manufacturing solutions, noting that efficient facility design is critical to accelerating therapeutic development. While the 2020 report initially focused on cell and gene therapies, subsequent editions have broadened to cover a wider range of therapeutic categories. The latest version takes a more holistic view, examining facilities in their entirety and how technology and operational trends intersect in biomanufacturing.
Walters added, “This report serves as an industry benchmark, providing insights from subject matter experts that reflect both the current state and future direction of biomanufacturing.”
CRB’s 2024 Horizons: Life Sciences report emphasizes aligning facility design with the product life cycle to meet evolving industry needs. A significant focus of the report is the integration of digitalization, continuous manufacturing, and artificial intelligence (AI), all essential for enhancing efficiency and adaptability. This report sets a new standard for innovation and sustainability in biomanufacturing facilities, enabling manufacturers to swiftly respond to market demands while maintaining high-quality outputs. Key findings include:
AI and Robotics: Revolutionizing the Laboratory & Warehouse
The integration of artificial intelligence (AI) and robotics is a key theme in this year’s Horizons report, reflecting a major shift in laboratory operations. Eighty percent (80%) of respondents have implemented or plan to implement AI within the next three years, making automation and data-driven systems standard practice in research environments.
AI’s ability to analyze large datasets and run complex simulations is revolutionizing both research and manufacturing, delivering faster and more accurate results. In manufacturing, robotics streamlines routine tasks like material handling and quality control, enhancing speed and precision. This automation improves consistency, reduces human error, and minimizes reliance on manual processes, saving time and cutting costs. As a result, AI and robotics are transforming drug discovery, development, and manufacturing, where speed to market and reliable data are critical for success.
Manufacturers are increasing inventory in their warehouses and holding it for longer by leveraging automated storage and retrieval systems and autonomous mobile robots to create more efficient warehouse operations. Currently, 1/3 of manufacturers are using these advanced technologies to help drive down costs.
Continuous Manufacturing: Transforming Production Processes
Another key trend identified in the Horizons report is the life sciences industry’s shift towards continuous manufacturing. This production method, which allows for the constant creation of products rather than traditional batch-based production, is gaining traction across the sector. The report reveals that 75% of respondents are either using or planning to adopt continuous manufacturing technologies within the next five years.
Continuous manufacturing offers key advantages over traditional batch methods, including increased efficiency, reduced downtime, and greater flexibility. Unlike batch systems that require stopping for cleaning or quality checks, continuous processes allow for seamless production, resulting in faster cycles, lower costs, and improved quality control.
For pharmaceutical and biotech companies, especially those producing complex biologics or personalized therapies, continuous manufacturing enables quicker scaling and greater agility in meeting market demands, making it an essential tool for the industry.
Continuous Purification: A Growing Focus on Downstream Efficiency
While continuous manufacturing focuses on production processes, continuous purification is emerging as a key area of focus for the life sciences industry, particularly in the context of biologics and advanced therapies. According to the report, the adoption of continuous purification technologies is expected to grow more than fourfold over the next decade.
Continuous purification enhances downstream processing efficiency, crucial for industries where product purity and quality are vital. Unlike traditional methods that are slow and resource-intensive, continuous systems streamline operations, enabling higher throughput and cost reduction. This shift is particularly important for companies working with monoclonal antibodies, gene therapies, or cell therapies, where speed and precision are essential. As more companies adopt continuous purification, it is poised to become a standard practice in biologics manufacturing, accelerating therapy development and reducing time to market.
Operator-Free Filling: The Future of Drug Production
One of the more futuristic trends highlighted in the report is the growing interest in operator-free, or “lights-out,” drug production systems. The report reveals that 91% of respondents believe operator-free filling will be the future of drug production, a trend that could revolutionize sterile manufacturing.
While the concept of fully automated, human-free production lines may still be years or even decades away, the industry is already making significant strides in this area. Operator-free filling systems would reduce the risk of contamination, a key concern in the production of sterile injectables and biologics. By eliminating the need for human intervention in critical processes, manufacturers can ensure higher levels of safety, consistency, and efficiency.
In addition to safety benefits, operator-free filling has the potential to dramatically cut labor costs. Automated systems can run 24/7, reducing downtime and increasing productivity. As the technology continues to evolve, it’s likely that more companies will invest in these systems, pushing the boundaries of what’s possible in pharmaceutical manufacturing.
Sustainability: Driving the Adoption of New Technologies
Sustainability has become a top priority for life science companies as they seek to reduce their environmental impact while maintaining efficiency and profitability. The Horizons report shows that 87% of respondents are either operating with renewable electricity or plan to make the transition by 2030, underscoring the industry’s commitment to greener practices.
The drive for sustainability is accelerating the adoption of energy-efficient manufacturing equipment and advanced recycling systems, enabling companies to reduce their carbon footprint and cut costs. As businesses prioritize eco-friendly practices, sustainability becomes a competitive advantage, attracting investment and securing contracts in markets that value corporate responsibility.
Financial Considerations: The Cost of Innovation
While the trends identified in the Horizons report highlight exciting technological advancements, they also raise questions about cost and capital investment. Many companies are eager to adopt new technologies, but the report shows that one in three respondents is focused on automation and digitalization improvements as a capital investment priority, indicating a split in how much they’re willing to spend on modernization efforts.
High costs pose a significant barrier to adopting advanced technologies, especially for smaller companies and startups. In labs and warehouses, the expenses associated with robotics, AI, and continuous systems can be prohibitive. Even larger companies must plan carefully to allocate capital efficiently across production processes. As firms modernize their facilities, balancing innovation costs with profitability will be a key challenge, but those who succeed will be well-positioned to lead the industry.
Conclusion: A Roadmap for the Future of Life Sciences
The Horizons: Life Sciences 2024 report provides a roadmap for the future of biopharmaceutical manufacturing, highlighting trends like AI and robotics adoption, continuous manufacturing, and operator-free filling. Companies in the life sciences sector must stay ahead of these developments to remain competitive and drive growth. By embracing new technologies and prioritizing sustainability, they will lead the industry into an exciting future.
Peter and Nicole Lane, Senior Strategic Marketing Manager at CRB, will present the 2024 Horizons: Life Sciences report this Thursday (10/24/24) at CRB’s Maryland Office in Rockville, MD, as part of the office’s tenth-anniversary celebration. The event will embrace the Oktoberfest theme, featuring Jon Rowley, Founder & Chief Product Officer at RoosterBIO Inc. and Partner at Funktional Brewing, one of Maryland’s emerging breweries, showcasing their innovative Hazy IPA!
