153: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos - Part 1

Smart Biotech Scientist | Master Bioprocess CMC Development, Biologics Manufacturing & Scale-up, Cell Culture Innovation

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As the biotechnology sector races toward digital transformation, the buzz around Industry 4.0 - with its promise of interconnected systems, automation, and data-driven operations - has never been louder. But is the industry truly ready?

In this episode, we speak with Tiago Matos, Associate Principal Scientist/Associate Director in Bioprocess Drug Substance and Commercialization at Merck & Co., who brings a grounded, insider view. Despite the hype, he says most of biopharma is still operating at an “Industry 3.2” level.

With over a decade of experience in biologics and vaccines, Tiago leads teams pushing digital innovation forward - through tools like digital twins, advanced control strategies, and smart manufacturing platforms.

Key takeaways from this episode:

• Biotech is slowly transitioning toward true Industry 4.0, through collaboration and strategic leadership.
• Digital twins aren’t for everything. Focused use in platform processes yields the best return - broad implementation can be costly and complex.
• Regulators are ready. Far from being a barrier, they’re encouraging innovation and open to new ideas.

Curious to learn more? Check out the full blog post for deeper insights, and let us know your thoughts in the comments - how close do you think biomanufacturing is to a true digital revolution?

Here is what other guests had to say on this topic:

• Episodes 5-6: Hybrid Modeling: The Key to Smarter Bioprocessing with Michael Sokolov;
• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli;
• Episodes 121-122: The Transformative World of Digital Solutions in Bioprocessing with Simon Wieninger.

Connect with Tiago Matos:

LinkedIn: www.linkedin.com/in/tiagobmatos

Merck & Co.: www.merck.com

Next step:

Transform your bioprocess development strategy with a complimentary consultation. Schedule your expert session: https://bruehlmann-consulting.com/call

Ready to scale up? Join our exclusive 1:1 Strategy Call and learn proven methods to reduce development and manufacturing costs while maintaining product quality. Our bioprocess experts will help you navigate complex bioprocessing challenges and regulatory requirements. Limited spots available: https://stan.store/SmartBiotech