Continuous Manufacturing Systems Market

Continuous Manufacturing Systems Market: Distribution by Type of Molecule, Type of Equipment, Stage of Manufacturing, Scale of Manufacturing and Geography (North America, Europe and Asia Pacific): Industry Trends and Global Forecast, 2021-2030

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Continuous Manufacturing Systems Market

The continuous manufacturing systems market is estimated to be worth $445 million in 2021 and is expected to grow at compounded annual growth rate (CAGR) of 12% during the forecast period. Pharmaceutical manufacturing processes are complex, time consuming, as well as cost intensive. In fact, it is estimated that production inefficiencies and product recalls (owing to manufacturing errors) are responsible for annual losses amounting to around USD 50 billion. Given the ever-increasing demand for pharmacological interventions, and the introduction of new and sophisticated therapeutic modalities, drug substance manufacturers are gradually opting for more advanced manufacturing solutions, such as continuous flow reactor. When compared to the conventional batch manufacturing process, the continuous mode of production has been demonstrated to allow significant cost savings (around 40% to 50% of expenditure when using traditional equipment).  According to the USFDA, using the continuous approach, it is even possible for industry stakeholders to significantly abbreviate production time; for instance, a drug that previously required a month to manufacture, can now be produced in a single day. Continuous processing also enables manufacturers to circumvent concerns related to equipment downtime, and use the entire capacity of production lines, while simultaneously testing the quality of products / production intermediates. Moreover, a continuous manufacturing facility requires 70% less area than a plant that is designed for running batch processes; this enables additional savings, in terms of facility operation costs. Further, continuous manufacturing processes can be automated, and the affiliated equipment usually includes a variety of advanced features that offer real-time visibility on various important parameters. Overall, the adoption of continuous flow reactor technologies is believed to possess the potential to notably improve productivity, while minimizing batch-to-batch variability. So far, the US FDA has approved four therapies that were produced using the continuous manufacturing approach. In addition, there are over 20 product candidates that are currently being manufactured via the same approach. 

Considering the various advantages of continuous manufacturing, pharmaceutical developers are gradually becoming more receptive to adopting such solutions. As a matter of fact, the recent surge in demand for pharmaceuticals amidst the COVID-19 pandemic, has served to create a strong case for pharmaceutical companies to develop the means to produce drugs faster. Moreover, the Centre for Drug Evaluation and Research (CDER) and US Biomedical Advanced Research and Development Authority (BRADA), are currently working closely to promote the use of continuous manufacturing for the production of therapeutics for medical emergencies. As a result, several industry stakeholders that are involved in drug development and production, have already made significant investments towards acquiring continuous manufacturing capabilities and the associated expertise. On the other hand, there are several companies that are now offering continuous manufacturing equipment that contain process analytical technologies (PAT) and advanced sensors. Further, many innovators claim to be engaged in improving the continuous manufacturing process, developing advanced variants of currently available processing systems, and optimizing on the cost of such solutions. The aforementioned developments are anticipated to result in an increase in adoption of continuous processing technologies, during the forecast period. 

Context of Continuous Manufacturing Systems Market List of Continuous Manufacturing Equipment Providers in Continuous Manufacturing Systems Market Market Landscape and Market Trends in Continuous Manufacturing Systems Market

Key Companies in Continuous Manufacturing Systems Market

Examples of key companies engaged in continuous manufacturing system market (which have also been profiled in this market report; the complete list of companies is available in the full report) include Corning, Glatt, IKA, Kilburn Engineering, Thermo Fisher Scientific, Eppendorf, Merck Millipore, Pall, Sartorius and TA Instruments. This market report includes an easily searchable excel database of all the companies providing continuous manufacturing systems including perfusion bioreactors, continuous mixers, blenders, grinders and others, worldwide.

Recent Developments in Continuous Manufacturing Systems Market:

Several recent developments have taken place in the field of continuous manufacturing systems market. We have outlined some of these recent initiatives below. These developments, even if they took place post the release of our market report, substantiate the overall market trends that have been outlined in our analysis.

  • In August 2023, KORSCH announced the acquisition of  MEDELPHARM  with an aim to strengthen its  product development, scale-up, high-speed production, multi-layer, continuous manufacturing, and high-containment applications. 
  • In May 2023, WuXi STA launched first continuous manufacturing line for oral solids with an aim to enhance oral drug development solution, enabling higher yields and shortened timelines to market.

Scope of the Report

The “Continuous Manufacturing Systems Market by Type of Molecule (Small Molecules and Biologics), Type of Equipment (Mixers, Granulators, Continuous Bioreactor / Reactors and Others), Stage of Manufacturing (Upstream and Downstream Process), Scale of Operation (Preclinical / Clinical and Commercial) and Geography (North America, Europe and Asia Pacific), 2021-2030” market report offers an elaborate study of the current market landscape, market size, market share, market growth, market forecast, market outlook and future opportunities of the continuous manufacturing systems market. The market research report features an in-depth analysis, highlighting the diverse capabilities of stakeholders engaged in continuous manufacturing systems market. In addition to other elements, the market research report includes:

  • A detailed assessment of the current market landscape of continuous manufacturing equipment for small molecule drugs, along with information on type of equipment, type of manufacturing process (only continuous and batch continuous), stage of manufacturing (upstream process and downstream process), scale of operation (preclinical / clinical and commercial) and type of product (single purpose and multipurpose equipment). In addition, the chapter highlights the analysis of equipment provider(s), based on various parameters, such as year of establishment, company size, location of headquarters and key players. 
  • A detailed assessment of the current market landscape of continuous manufacturing equipment for biologic drugs, providing information on type of equipment, type of manufacturing process (only continuous and batch continuous), stage of manufacturing (upstream process and downstream process) and scale of operation (preclinical / clinical and commercial). In addition, the chapter highlights the distribution of equipment provider(s), based on various parameters, such as year of establishment, company size, location of headquarters and key players.
  • An in-depth analysis of the various patents filed / granted related to continuous manufacturing and affiliated equipment, till 2020, along with information on key parameters, such as publication year, geography, CPC symbols, emerging focus areas, type of applicant and leading industry / non-industry players (in terms of size of intellectual property portfolio). Further, it features a 3-D bubble analysis (based on publication year, patent citation count and extended geographical reach) and a detailed patent valuation analysis.
  • An insightful 4-D representation, highlighting the competitiveness analysis of continuous manufacturing equipment providers for small molecules and biologics, across key geographical areas, taking into consideration the company experience (experience of the company), product expertise (scale of operation, type of manufacturing process, types of equipment and type of product), product portfolio (number of equipment) and company size (small, mid-sized and large companies).
  • A case study highlighting the contract manufacturing organizations that claim to have the required expertise and capabilities related to continuous manufacturing, along with information on relevant parameters, such as year of establishment, company size, purpose of manufacturing (in-house and contract service), scale of operation (preclinical, clinical and commercial), type of drug molecule, location of headquarters and location of continuous manufacturing facilities.
  • Tabulated profiles of key companies (shortlisted based on number of equipment provided) providing continuous manufacturing equipment for small molecules and biologics manufacturing. Each profile provides an overview of the company, list of continuous manufacturing equipment, financial information (if available), and details on recent developments as well as an informed future outlook. 

The key objective of continuous manufacturing systems market report is to provide a detailed market analysis in order to estimate the existing market size, market value, statistics and future opportunity for continuous manufacturing systems market during the forecast period. We have provided an informed estimate to the likely evolution of the market in the short to mid-term and long term, for the forecast period of 2021-2030. Our year-wise projections of the current and future opportunity have further been segmented based on [A] type of molecule (small molecule and biologic), [B] type of equipment (mixers, granulators, continuous bioreactor / reactors and others), [C] scale of operation (preclinical / clinical and commercial), stage of manufacturing (upstream and downstream process) and [D] geography (North America, Europe and Asia Pacific).

Patent Analysis in Continuous Manufacturing Systems Market Company Competitiveness Analysis in Continuous Manufacturing Systems Market Market Forecast and Opportunity Analysis in Global Continuous Manufacturing Systems Market

The opinions and insights presented in this market research report were influenced by discussions conducted with several stakeholders in continuous manufacturing systems market. The market report features detailed transcripts of interviews held with the following individuals:

  • Andrea Adamo (Founder and Chief Executive Officer, Zaiput Flow Technologies)
  • Bayan Takizawa (Co-Founder and Chief Business Officer, CONTINUUS Pharmaceuticals)
  • Graeme Cruickshank (Chief Technology and Innovation Officer, Center for Process Innovation)
  • Nick Thomson (Senior Director Chemical Research and Development, Pfizer)
  • Anonymous (Senior Manager, Continuous Manufacturing Business Development, Patheon)

All actual figures have been sourced and analyzed from publicly available information forums and primary research discussions. Financial figures mentioned in this market report are in USD, unless otherwise specified.

Frequently Asked Questions

Question 1: What are continuous manufacturing systems?

Answer: Continuous manufacturing systems encompass equipment used in bioprocessing applications to obtain a product nonstop, without any hindrances or pauses between batches.

Question 2: How big is the continuous manufacturing systems market?

Answer: The continuous manufacturing systems market size is estimated to be worth $445 million in 2021.

Question 3: What is the projected market growth of the continuous manufacturing systems market?

Answer: The continuous manufacturing system market is expected to grow at compounded annual growth rate (CAGR) of 12% during the forecast period 2021 – 2030.

Question 4: Who are the leading equipment providers in the continuous manufacturing systems market?

Answer: Examples of key companies engaged in continuous manufacturing systems market (which have also been profiled in this market report; the complete list of companies is available in the full report) include Corning, Glatt, IKA, Kilburn Engineering, Thermo Fisher Scientific, Eppendorf, Merck Millipore, Pall, Sartorius and TA Instruments.

Question 5: How many companies are currently engaged in the continuous manufacturing systems market?

Answer: Over 80 companies are currently engaged in the continuous manufacturing systems market, offering services for pharmaceutical and biotech companies.

Question 6: How many patents have been filed / granted related to the continuous manufacturing systems?

Answer: Close to 1,000 patents have been filed / granted related to the continuous manufacturing systems, indicating the research and development efforts of stakeholders in this industry.

Question 7: What is the cost saving potential of continuous manufacturing operations?

Answer: Continuous manufacturing operations can save up to 50% in the final cost of the product, through the use of advanced technical solutions.

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