The Future of ATMPs

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July 2025

In part one of our two-part series on the future of ATMPs, David Phasey, Business Development Director at 3P Innovation, joins the podcast to discuss the drivers of the high cost-of-goods (COGs) for ATMPs and how automation can help reduce these COGs in the future.  

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    David Phasey
    Business Development Director
    3P Innovation
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    Welcome to the ISPE podcast, Shaping the Future of Pharma,

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    where ISPE supports you on your journey, fueling innovation, sharing insights,


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    thought leadership, and empowering a global community to reimagine what's possible.


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    Hello and welcome to the ISPE podcast, Shaping the Future of Pharma. I'm Bob Chew, your host,


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    and today we have another episode where we'll be sharing the latest insights and thought


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    leadership on manufacturing technology, supply chains, and regulatory trends impacting the


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    pharmaceutical industry. You will hear directly from the innovators, experts, and professionals


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    driving progress and shaping the future. Thank you again for joining us, and now


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    let's dive into this episode. Our topic today is the future of advanced therapeutic medicinal

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    products, or ATMPs. To share more about this topic, I would like to welcome David Phasey,

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    Business Development Director at 3P Innovation, who recently presented at the 2025 ISPE

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    Europe Annual Conference in London. David, welcome to the podcast. We're glad to have you with us.

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    Thank you, Bob. It's great to be here, and hopefully a good topic to discuss.

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    Great, and I recall your presentation was well-received with a lot of good questions

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    from the audience, so we'll follow up with a few additional questions here.

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    So, David, in your opinion, what are the biggest drivers of the high cost of these advanced

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    therapies? Is it low volume? Is it a highly manual process? Is it the discovery costs?

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    Is it the supply chain logistics? Is it the therapeutic value to the patient, or something

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    else? Yeah, this is a really good question in that ATMPs are, of course, a broad range of different

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    therapy types, very different manufacturing chains, and as I've been researching this topic

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    conducting literature reviews and seeing what available information there is,

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    unsurprisingly, there isn't necessarily a completely fixed answer to the question.

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    So, I work, of course, in the automation side of the industry rather than a therapy developer

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    myself, and I'm aware that a number of large pharma companies, BMS, for example, have done

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    value stream mapping themselves to look at the manufacturing costs of their own products,

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    and, of course, they will have a cost model specific to their product. So, the way in which

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    I and the ISP team chose to look at this topic was perhaps rather than necessarily the biggest

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    drivers of cost, some of those reasonably well sort of understood and documented already in terms

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    of the drug discovery and the increase in cost of those. There's other good studies out there

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    on transportation costs, for example. There's a couple of items that you highlighted in your

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    question. So, the way in which we sort of try to rephrase that for ourselves was actually where

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    do we feel that as a community we can add the most value? So, where is actually the greatest

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    opportunity to reduce cost? And it struck us that there's already a reasonable degree of

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    effort being put into understanding transportation costs, and, of course, a lot of that came out of

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    recent events. So, instead, actually, what we focused on and where we saw the greatest

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    opportunity for reducing cost is in and around the manufacturing processes itself. So, you

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    mentioned in there manual processes, and really there is a significant cost associated with the

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    largely manual and semi-automated processes which have historically been laboratory-based,

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    and that transition to GMP does a significant cost with that. And so, that's where we decided

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    really to focus in on and explore because that's what we saw as an engineering community where we

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    felt there was most opportunity to add value and contribute to that reduction in cost.

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    Okay. So, my limited understanding, you've got a highly manual process, so you have

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    training of the people, you have the cost of the manpower, but I'm also aware that there's a pretty

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    significant effort around a myriad number of deviations that typically occur from a manual

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    process. Are there other aspects, and what's the low-hanging fruit here in the manual process

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    to implement automation and have the biggest positive cost reduction impact?

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    Yes. So, the way that we've been looking at that is the answer is perhaps a little different

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    depending on which the scale of manufacturing and the type of the ATMPs, but if we consider

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    probably the most common examples in describing that clean room, that manufacturing suite,

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    as you talked about, they're largely manual processes with individual pieces of automation

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    for individual process steps. Now, in that type of environment, surprisingly, it may actually be

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    that the automation is not the mechanization of process steps, and I think that's where a lot of

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    people would traditionally think of automation is actually the mechanization and that being the

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    opportunity. We see a lot about robotics, and that's very exciting, but when the process is,

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    you actually have a therapy SAT incubating or whatever the process step is within a piece of

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    equipment for a significant period of time, the mechanization doesn't have an immediate

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    transformational impact, and therefore, actually, when we're looking at those lower scales, the

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    opportunities appear to be more around process optimization and increase in quality, and really,

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    I think that comes about through instrumentation and therefore digitization of the processes,

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    and some of the tools to support that, the automation might be as simple as, for example,

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    a barcode scanner, the ability to streamline processes. I've done some work in a completely

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    parallel, but interesting sector of sterile instrument processing, and there are a number of

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    interesting observations in that, in that from the outside, when you first look at it, you would say

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    this can't be automated, it is really difficult, there are lots of unique process steps, it's

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    largely manual, you can't really automate this, you're a bit stuck, and I've seen some really

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    superb examples of lean manufacturing thinking being brought into that sector, and having an

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    extraordinary impact on the output of a facility purely based upon lean manufacturing processes

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    of studying the utilization of people within that room, the utilization of tools,

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    tracking materials through that room, and thereby increasing utilization of the assets that already

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    exist, and having a closer eye on the quality of those processes of which instrumentation and

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    digitization can help. So, a different form of automation, I think, would be, could offer

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    people that ability to make an initial transformation change, and that's where I'd see that

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    that loafing hanging fruit being. So, I recall seeing presentations at conferences, probably in the last

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    year, two different ones, one was this sterile clean room in a box, it sat on a coffee table,

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    almost, it was a Swiss company, and it did some of the rudimentary manipulations

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    around cell and gene therapy, so that was automating the manual process, but the other

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    one that I recall was kind of like a time motion study, almost, it was done by some sort of

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    visual tool with AI, I'm not sure, but it studied the detailed hand motions of the operator,

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    picking up the tools, making the connections, and it allowed to optimize and simplify

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    what the operator was doing. Is that the kind of thing that you're talking about?

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    Absolutely, I mean, that can have an impact in both, from a quality perspective, and certainly

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    those type of tools are well understood, used for improving good aseptic process, and therefore

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    you can end up with a double impact on cost there, in that, yes, you can make an efficiency

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    improvement in the way in which the operators in the clean room are able to produce that product,

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    but probably the biggest gain is in yield, because if they're not making mistakes in the process,

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    and you're able to generate a higher yield with that batch, or not have any failures within the

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    batch of manufacturing, that obviously is far greater, or can be potentially far greater cost

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    saving than efficiency, so you can end up with both, and yes, that's the type I'm referring to.

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    It perhaps doesn't sound quite as glamorous as implementing robotics and things, which you might

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    immediately visualize, but in answering your question around low-hanging fruit, it's those

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    small steps that can actually have maybe even tens of percent improvement in the efficiency

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    of a process, but without actually necessarily spending money in order to achieve it, because

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    that's one of the other factors I've seen frequently come into these arguments, is

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    the instinct is to actually spend money to save money, and you can fall into the trap of actually

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    having dis-economies of scale, where you actually introduce more automation, and the payback

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    doesn't really arrive, depending on the throughput of your manufacturing process.

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    Now, I also know about AI being used for vial inspections and that kind of thing.

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    Yes.

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    What about a camera with AI behind it that is watching everything that the operator does,

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    and could it detect and then analyze deviations visually and resolve them

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    almost instantly as either something significant, hey, high probability you just introduced

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    contamination, or yeah, it was a deviation, but it really doesn't matter. Is that an application

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    of technology here?

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    Yeah, and it's interesting you ask that question, because I would have said only a few

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    weeks ago that that was an interesting future technology. What I hadn't realized until I went

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    to another presentation recently is that's now a current technology that exists. It's been tested.

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    I'm sure people can find that company, and I found it really interesting. It was doing exactly

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    as described there, is that by studying many, many sample images, and they were able to use

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    AI to say, well, if action X is acceptable, is good aseptic processing, and action Y is not,

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    and a good number of images of examples, the AI was then able to identify

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    actions which were not considered best practice.

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    Do we think that that technology is more, I'll say, bulletproof than a human

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    analyzing the same information and making determinations?

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    That's a good question. I think where I saw, when I saw this presentation, where I saw

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    immediate value is the fact that you can provide this ongoing monitoring of a process that isn't

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    perhaps practicable to have, in some instances, but in others not, where you have an operator

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    and then another operator watching over their shoulder. Therefore, it probably adds that

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    additional assurance, because a lot of these processes are particularly challenging to

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    perform and remember each step and perform everything.

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    Exactly right. What do you see as the current barriers to adoption of truly impactful,

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    from a cost perspective, automation into ATMP manufacturing?

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    So, in that last question, I was answering, sort of considering where we are today in a more

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    manual cleanroom and describing some of the advantages we can see from relatively small

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    changes. If we think now very much towards the future, and I think that's where you're going

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    with that question, perhaps a little, quite a way into the future, really the fundamental

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    change, as I see it, is actually driven by the consumables.

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    And this was something I was talking about in my presentation. If you look to other sectors,

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    whether in the pharmaceutical or elsewhere, part of the, or a key part of that journey,

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    has been around standardization of componentry. USB, for example, USB-C and the standardization

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    of that connector. Now, that's actually more from the, in that instance, from the consumer benefit

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    perspective. But in this instance, standardization of consumable components, I see as being one of

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    the key milestones in enabling cost reduction. There's reasons for that. Now, it's because,

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    one, you can actually allow a lot of mechanization style automation to be designed

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    around these common sets of components and consumables. That in itself promotes competition

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    within that space. But also, if you have consumables that are themselves designed to

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    be automated in their actuation, which historically they haven't been, they've

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    been designed in classic sterile connectors, are designed for dexterous use of thumbs, etc.,

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    not operated by a robot. So, I suspect we should hopefully see a transformational

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    change in consumables and that's unlocking mechanization style automation. And along

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    with that, as we get more standardization in consumables, and whether that be bioreactors

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    themselves, tubing sets, sterile connectors, filtration sets, etc., that should also enable

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    larger volumes of componentries and more assurance in supply chains that allows the cost of those

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    components to come down. So, you can end up with a snowboard effect as we start to coalesce

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    around more standardized componentry. At the moment, I see it that we're in a diversification

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    phase as everyone's exploring different technologies. And again, you see these

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    parallels happen in other industries. And there is good pattern of this in the industrialization

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    of other sectors. You go through this growth phase of diversification as people try and explore

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    what's the best way of solving this problem, what are all these best technologies.

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    But after a number of years, history shows us we always end up coalescing around a number of

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    key solutions which the industries unify around, coalesce around, and that then unlocks the next

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    phase. So, that's where I see it really. It's probably the consumable as the core.

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    Okay. In your talk regarding economies of scale, you mentioned autologous versus allergenic

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    therapies. And you also mentioned small versus large patient populations. Now, to a large degree,

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    aren't these factors beyond the control of the manufacturer and instead driven by the specific

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    disease indication and patient population and genetic profile in terms of batch size

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    and patient populations? Yes, absolutely right. And so, the reason for highlighting that was

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    really twofold. Firstly, it's my aim in the content I'm sort of producing here is I'm

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    wanting to share information with the community and seek additional input from the community.

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    Seek additional input from the community. And in this instance, I think there is a…

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    If I make the assertion that we are going to see a reduction in the cost of goods,

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    the natural question that comes immediately back is, well, to what extent? Where are we going to

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    see it? By how much? That's, of course, a very, very difficult question. So, there was a particular

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    table that I put up in the presentation where I'm trying to add a degree of clarity into what

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    does cost of goods actually mean? What are all of the drivers? And where does the manufacturer

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    of ATMPs compare and contrast with other sectors, but also other pharmaceutical products? And

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    the patient population is obviously a key component in that. And awareness of it is necessary in order

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    to understand what the limitations are. So, that's one aspect is really helping try and as we try and

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    pick apart some clarity. The other component is actually when I was talking about standardisation,

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    we're in this diversification stage. We're obviously diversification in terms of

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    number of therapy types, the manufacturing process associated with them, and the technologies

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    associated with it. So, there's diversification in many, many different areas. That means that

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    it is quite hard to standardise. So, by reflecting back this diversification, my aim is then to try

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    and help the community identify where we can start seeing these pockets of similarity. Because

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    the sooner we start identifying where similarities exist, in therapy types A, B, and C,

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    whilst they are wildly different, actually, there's commonalities in these areas. If we can unify

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    manufacturing processes in there, then we can then effectively increase the size of the patient

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    population. Not by changing the therapy itself, which of course, as manufacturers, we can't do,

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    but by creating commonality within pockets of the manufacturing process. I realise that's a little

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    abstract in my description, but hopefully that makes sense.

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    So, what about distributed manufacturing, or basically the idea of a clean room trailer

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    in the hospital parking lot that has the ability to produce any number of these

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    ATMPs on demand? Is that feasible in the future, do you think?

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    Yes, feasible, of course, opens up a number of different ways of looking at that from a

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    technological perspective. I don't see any technological reason why that is not possible.

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    We've already seen some examples of people doing that kind of approach.

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    The challenges probably come more, actually, when considering costs

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    about utilisation. It's something we haven't discussed in this podcast yet, but it is actually

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    one of the surprises to me, but probably not surprises to an accountant, as it were,

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    when looking at the costs of goods and where these costs come from. Utilisation is probably

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    one of the biggest cost drivers, in that if you have purchased all of this capital equipment in

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    the form of the trailer and the equipment that goes in it, the cost of the goods relies probably

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    on a high degree of utilisation of that equipment. Now, in conventional manufacturing,

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    if you're doing, say, a vial filling line, it's relatively easy to plan for the utilisation of

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    that. You can reasonably forecast how many batches you're going to produce a year, and therefore,

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    you can work out on a unit manufacturing basis what the cost of producing that individual vial is.

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    When we're talking about ATMPs, that becomes a considerably more difficult question,

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    and from some of the studies, as I've seen, that becomes one of the challenges, is that

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    you invest in this infrastructure, but you have far less control over the patient population demand

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    upon that service. And if you end up with a relatively low utilisation, you end up,

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    unfortunately, with a relatively high cost. And I think that's one of the areas

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    where I suspect, I very much hope, I'm sure we all hope, that the change in the style of the ATMPs,

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    the efficacy of them, actually means that we will end up moving more towards first-line treatments,

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    larger populations, and making these types of systems affordable in that you can achieve a

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    high utilisation from them because they become more norm. I suspect what we're going to see

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    in the industry is this snowballing type effect where one impacts the other.

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    Well, this has been a very interesting discussion. To recap, we talked about various ways that

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    automation could be introduced or expanded within the manufacture of ATMPs, not just robots,

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    which a lot of people think about, but how to supplement the human, make the human more

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    efficient, make the process more efficient, and all the quality system elements that go with it.

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    So, there's no single silver bullet, it seems. Would you agree with that?

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    I'm afraid so, yes. It is particularly complicated, but good opportunities at the same time.

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    Well, great. That brings us to the end of another episode of the ISPE podcast,

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    Shaping the Future of Pharma. A big thank you to our guest, David Fazey, for sharing his findings

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    on what the development of products in other sectors can tell us about how the potential

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    >reduction of cost of goods can be achieved in the future with respect to the manufacture of ATMPs.

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    Be sure to subscribe so you don't miss future conversations with the innovators,

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    experts, and changemakers driving our industry forward. On behalf of all of us at ISPE,

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    thank you for listening, and we'll see you next time as we continue to explore the ideas,

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    trends, and people shaping the future of pharma.

Listen to Past Episodes

In this episode, host Bob Chew is joined by Martin Orcoyen, President of ISPE Argentina Affiliate, Ricardo Miranda, President of the ISPE Brazil Affiliate, and Alejandro Bustamante, President of the ISPE Mexico Affiliate, to discuss the jointly