Equipping the next generation of biopharmaceutical engineers for continuous bioprocessing remains one of the industry's most pressing workforce challenges, and a new partnership between Sartorius and the National Institute for Bioprocessing Research and Training (NIBRT) is directly targeting that gap. The collaboration will establish what both organisations describe as the world's most comprehensive training center for intensified and continuous bioprocessing, based in Dublin, Ireland. Sartorius will equip the facility with the Pionic® platform, its end-to-end modular cGMP solution for continuous bioprocessing, with operations beginning in the fourth quarter of 2026.
Training for Continuous Bioprocessing Has Not Kept Pace with the Technology
The biopharmaceutical workforce has not kept pace with the industry's accelerating shift from batch production to continuous bioprocessing. In a traditional fed-batch model, each unit operation runs in isolation; training is modular and step-by-step. Continuous bioprocessing links perfusion bioreactors, multicolumn chromatography, viral inactivation, and ultrafiltration/diafiltration into a single integrated flow across upstream and downstream stages, demanding a fundamentally different understanding of process dynamics, analytical monitoring, and real-time control.
Working in analytical science?
Register for a FREE Separation Science account to subscribe to the Separation Science Newsletter.
Regulation has moved faster than workforce development. The FDA's ICH Q13 guidance (International Council for Harmonisation Q13, finalized in March 2023) provides a global harmonized framework for therapeutic proteins in continuous manufacturing, covering development, implementation, and lifecycle management. These are precisely the competencies a dedicated facility must convey.
"As biopharma manufacturing undergoes a major shift from batch processes toward more efficient, continuous processes, Sartorius is once again at the forefront of this transformation. While technological innovation is the first step, training current and future engineers and operators is critical to making the change a reality," remarks René Fáber, Head of the Bioprocess Solutions Division and Member of the Executive Board at Sartorius.
The Pionic® platform integrates five core modules:
- Pionic® Quad: Single-use multicolumn chromatography supporting 1-4 column operation for continuous capture and polishing
- Pionic® Spin: Automated continuous low-pH virus inactivation with plug-flow incubator design and 28-day process duration
- Pionic® Dual: Integrated normal flow filtration and continuous chromatography with in-line dilution via the Flow module
- Pionic® Cross: Single-pass tangential flow filtration (SPTFF) integrating ultrafiltration (UF1, UF2) and diafiltration (DF) steps in a single continuous operation
- Biobrain® automation: Modular automation platform with OPC UA connectivity, integrating with distributed control (DCS) and manufacturing execution systems (MES)
Which Manufacturing Workflows Benefit from Continuous Bioprocessing Training?
Monoclonal antibody manufacturers, biosimilar developers, vaccine producers, and contract development and manufacturing organizations (CDMOs) all benefit, as the Pionic® platform's modular design accommodates both stepwise intensification of individual unit operations and fully integrated end-to-end continuous processing. For mAb and biosimilar manufacturers under cost pressure, continuous bioprocessing offers demonstrable reductions in cost of goods and facility footprint. For CDMOs handling multiple products, the platform's fast changeovers and simplified GMP qualification reduce the operational risk of adopting new process modes.
| Application Area | Relevant Capability |
|---|---|
| Monoclonal Antibody Manufacturing | Multicolumn chromatography capture, continuous virus inactivation, SPTFF concentration |
| Biosimilars and Cost-Efficient Production | Reduced cost of goods, smaller facility footprint, higher annual batch throughput |
| Vaccines and Advanced Therapies | Integrated perfusion-compatible upstream and downstream processing, 28-day continuous run support |
| CDMOs and Multi-Product Facilities | Modular reconfigurability, fast changeovers, simplified GMP qualification |
| Academic and Regulatory Training | Hands-on cGMP-simulated environment, pilot-scale demonstrations, collaborative research |
The Process Intensification Training Center will anchor NIBRT's global network, reaching industry professionals and academic partners across Ireland, Europe, and beyond. It also provides a platform for collaborative research and pilot-scale process demonstrations.
Darrin Morrissey, CEO of NIBRT, notes: "This collaboration marks a significant step in advancing workforce training and supporting the transition toward intensified and connected manufacturing. By integrating the Pionic platform into our training facility, we will give biopharma professionals the chance to gain first-hand experience with cutting-edge technologies that drive process efficiency and performance."
Dublin Becomes a Dedicated Hub for Continuous Bioprocessing Workforce Training
The Sartorius-NIBRT partnership creates what both organizations describe as the world's most comprehensive hub for intensified and continuous bioprocessing training, directly targeting the skills gap that continues to slow industry adoption. More than 1,000 scientists, engineers, and students are expected to train annually from the fourth quarter of 2026, across both upstream and downstream process modes. Beyond the immediate training program, the facility extends NIBRT's global network to industry and academic partners in Ireland, Europe, and internationally, supporting collaborative research alongside hands-on process development.
This article is based on a press release issued by Sartorius and NIBRT and was produced under Separation Science's AI Editorial Guidelines.
