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

David Brühlmann - CMC Development Leader, Biotech C-level Advisor, Business Strategist

The Go-to Podcast for Biotech Scientists Who Want to Master Biopharma CMC Development and Biomanufacturing. **TOP 10 LIFE SCIENCES PODCAST** Are you ready to simplify bioprocess development and scale with confidence to reduce time to market? Are you feeling overwhelmed by the complexity and guesswork of biologics development and biomanufacturing? Do you wish you had more time to enjoy the beauty of science, without worrying about failing your cell culture process development and commercialization? There's a way to simplify and streamline so you can remove complexity, skip trials and errors, deliver your groundbreaking therapy to clinics and market without delay, and still enjoy every single step. I'm David Brühlmann, a biotech entrepreneur and strategic advisor who partners with C-level biopharma leaders to tackle one of our industry's biggest challenges: reducing manufacturing costs to make lifesaving therapies accessible to more patients worldwide. Through engaging conversations with industry pioneers and practical insights from the trenches, this podcast tackles the critical challenges in bioprocess CMC development and manufacturing of recombinant proteins and cell and gene therapy products. We cut through the complexity so you can: Master bioprocess development with confidence and clarity Excel at scale-up and manufacturing of biologics Transform your innovative therapy and manufacturing technology into market-ready solutions faster Optimize manufacturing costs without compromising quality Make data-driven decisions that reduce the risk of failure I can’t wait to help you do biotech the smart way. Grab a cup of coffee and your favorite notebook and pen. Now is the time to take your bioprocessing game to the next level. Ready to transform your biomanufacturing journey? Let's dive in! Next Steps: Book a free call to reduce biomanufacturing costs and make lifesaving therapies more accessible: https://bruehlmann-consulting.com/call 🧬 Ready to accelerate your IND timeline? Get the proven CMC Dashboard that's guided successful mAb programs from chaos to submission: https://stan.store/SmartBiotech/p/cmc-dashboard-for-biotech-founders Accelerate biologics development with expert guidance: https://bruehlmann-consulting.com Visit the Website: https://smartbiotechscientist.com Email us: hello@bruehlmann-consulting.com

  1. 1D AGO

    198: Mastering ADC Development: CDMO Strategies for Analytics and Scale-Up with Amanda Hoertz - Part 2

    What happens when the most complex molecules in biotech meet the organizational challenge of managing 300+ analytical scientists? The answer lies not just in the science, but in building systems that turn technical complexity into reliable delivery. In Part 2 of our deep dive with Amanda Hoertz, VP of Analytical and Formulation Sciences at KBI Biopharma, we shift focus from the molecular intricacies of ADCs to the operational mastery required to scale analytical development across multiple sites. Amanda reveals how her team achieves consistency across hundreds of scientists while maintaining the agility to pivot priorities in real time when critical programs need emergency support. This isn't just about managing people; it's about architecting systems that preserve institutional knowledge, accelerate method transfer, and deliver results when regulatory deadlines loom. What you'll discover: Seamless Project Handoffs Without Knowledge Loss: How KBI's stable team assignments eliminate the costly learning curves that plague most CDMO relationships, ensuring your molecule expertise stays with your program from development through commercial manufacturing.Organizational Scale Without Operational Chaos: The decision tree and layered reporting structure that allows 200+ analysts at a single site to function as a coordinated force, capable of rapid reprioritization and flood-level resource deployment when programs reach critical status.Digital Transformation That Actually Works: Beyond the automation buzzwords, Amanda walks through the practical realities of LIMS/ELN implementation, audit-compliant systems, and machine learning databases that transform raw data into defensible, actionable insights for complex biologics.Whether you're evaluating how analytical capabilities scale with program complexity, or seeking practical insights into leading technical teams through digital transformation, this episode delivers the operational intelligence that separates successful ADC programs from expensive failures. Connect with Amanda Hoertz: LinkedIn: www.linkedin.com/in/amanda-hoertz-3aba605 KBI Biopharma: www.kbibiopharma.com KBI Portal: www.standalone.kbi.bio Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call 🧬 Stop second-guessing your CMC strategy. Get an investor-ready CMC roadmap in 2 weeks, before mistakes cost you $2M+ and 18 months of delays. Secure your spot at https://stan.store/SmartBiotech/p/dont-let-cmc-kill-your-funding-round Support the show

    22 min
  2. 3D AGO

    197: Mastering ADC Development: CDMO Strategies for Analytics and Scale-Up with Amanda Hoertz - Part 1

    What if the key to unlocking ADC manufacturing success lies in abandoning the platform mindset entirely? Antibody-drug conjugates represent biotech's most promising weapon against cancer: precision-targeted therapeutics that deliver cytotoxic payloads directly to tumor cells while sparing healthy tissue. But beneath the clinical promise lies a manufacturing reality that's rewriting the rules of bioprocess development, demanding analytical strategies that most CDMOs simply aren't equipped to handle. In this deep-dive episode, David Brühlmann sits down with Amanda Hoertz, Vice President of Analytical and Formulation Sciences at KBI Biopharma, where she oversees 300+ scientists across the mammalian network. Amanda's team has cracked the code on some of the industry's most challenging ADC programs, achieving a remarkable 93% batch success rate by rejecting cookie-cutter approaches in favor of molecule-specific development strategies. What you'll discover: The Platform Fallacy: Why treating ADCs like standard monoclonals is costing companies millions and months of development time, and the bespoke analytical framework that's changing everything.Cytotoxic Payload Management: From free drug analysis to employee safety protocols, Amanda reveals the hidden complexities of handling molecules designed to kill cells, including the specialized facilities and analytical methods required for GMP manufacturing.Charge Heterogeneity Mastery: The analytical method that "keeps Amanda up at night," and the development strategies her team uses to achieve robust separation and qualification across multiple sites and analysts.This episode delivers the technical depth and strategic insights that bioprocess engineers need to navigate ADC development successfully. Whether you're evaluating CDMO partnerships, optimizing analytical methods, or scaling complex conjugates, Amanda's proven strategies will transform your approach to these game-changing therapeutics. Ready to master the analytical complexities that make or break ADC programs? Connect with Amanda Hoertz: LinkedIn: www.linkedin.com/in/amanda-hoertz-3aba605 KBI Biopharma: www.kbibiopharma.com KBI Portal: www.standalone.kbi.bio Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call 🧬 Stop second-guessing your CMC strategy. Get an investor-ready CMC roadmap in 2 weeks, before mistakes cost you $2M+ and 18 months of delays. Secure your spot at https://stan.store/SmartBiotech/p/dont-let-cmc-kill-your-funding-round Support the show

    26 min
  3. OCT 9

    196: Monolithic Chromatography Innovations: Solving High-Capacity Purification for Gene Therapy Vectors with Alois Jungbauer - Part 2

    What if solving tomorrow’s bioprocessing challenges meant questioning the very physics of chromatography and reimagining downstream processing from the ground up? For years, large biomolecules like viral vectors and exosomes have squeezed through the limitations of traditional chromatography, leaving scientists to wrestle with capacity trade-offs and slow mass transfer. But what if a fundamental shift could unlock breakthroughs for gene therapies, vaccines, and advanced biologics? In this thought-provoking episode, host David Brühlmann sits down with Alois Jungbauer, professor emeritus of downstream processing at BOKU University (Vienna) and scientific advisor at BioChromatographix International. Together, they examine the future of chromatography and downstream processing, exploring innovations that tackle the challenges of modern gene therapy, advanced therapeutics, and sustainability in manufacturing. Alois shares his perspective on anticipating industry needs, the importance of mentorship, and why the physical limits for purification of large biomolecules are yet to be reached. Episode Highlights: The difference between solving current problems and anticipating the needs of the next generation in biotech (00:00)The promise and technical details of monolithic chromatography and its application for large modalities like gene therapy vectors and exosomes (03:01)Explanation of “inverted morphology" and AXISFLOW™ in new chromatography materials (03:18)Challenges and opportunities in continuous gene therapy vector production, and why it’s not widespread yet (07:40)The critical role of sustainability in downstream processing, particularly water usage and its impact on the viability and costs of distributed manufacturing (10:30)The relationship between reducing water consumption, manufacturing footprint, and cost of goods (12:16)Advice on scientific career development: listening, reading, understanding future industry needs, finding a mentor, and having persistence (13:50)Broader reflections on the value of science, societal perceptions, and science communication in today’s world (17:34)Alois’s key takeaway: downstream processing for gene therapy has not yet reached its physical limits—there is still significant room for improvement (20:26)If you’re looking for fresh strategies to tackle the bottlenecks of large-molecule purification - and a candid perspective on where the real opportunities and societal responsibilities lie - you won’t want to miss this conversation. Connect with Alois Jungbauer at leading conferences, including Bioprocessing Summit and Bioprocessing International, or find the next integrated continuous biomanufacturing event where he’s co-chairing. Connect with Alois Jungbauer: LinkedIn: www.linkedin.com/in/alois-jungbauer-14984811 Website : www.biochromatographix.com Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call Preparing for your IND? We’re building a CMC Dashboard in Excel to help biotech founders track tasks, timelines, and risks in one place. Join the waitlist for early access at 🧬 Stop second-guessing your CMC strategy. Get an investor-ready CMC roadmap in 2 weeks, before mistakes cost you $2M+ and 18 months of delays. Secure your spot at https://stan.store/SmartBiotech/p/dont-let-cmc-kill-your-funding-round Support the show

    25 min
  4. OCT 7

    195: Monolithic Chromatography Innovations: Solving High-Capacity Purification for Gene Therapy Vectors with Alois Jungbauer - Part 1

    In this episode, host David Brühlmann is joined by Alois Jungbauer, Professor Emeritus at BOKU University, Vienna, and Scientific Advisor at BioChromatographix International. With over 40 years in bioprocess engineering and more than 400 published papers, Jungbauer offers a unique perspective on how downstream processing and purification technologies have evolved and where they’re headed next. Alois shares his unconventional journey into the world of biotech, starting from humble beginnings on an Austrian farm, and discusses key turning points that have shaped the industry. Together, they explore the latest challenges triggered by high cell culture titers, new therapeutic modalities, and the drive for automation and process integration in manufacturing. In this episode: Why the gap between upstream and downstream processes remains a core bottleneck (03:27)How rigid and convective chromatography materials changed throughput and efficiency (06:56)The shift in purification strategies with skyrocketing titers in cell culture (08:43)Automation and integrated biomanufacturing: their role in making processes more robust and continuous (10:20)Misconceptions around resin costs in full-scale versus clinical-scale manufacturing (12:10)What automation and process monitoring mean for real-time release and factory scheduling (14:05)The resurgence and application of displacement chromatography for gene therapy vectors (15:49)Whether you’re deep into process development or just curious about the next wave in biotech manufacturing, Alois Jungbauer’s insights offer valuable context for the road ahead. Connect with Alois Jungbauer: LinkedIn: www.linkedin.com/in/alois-jungbauer-14984811 Website : www.biochromatographix.com Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call Preparing for your IND? We’re building a CMC Dashboard in Excel to help biotech founders track tasks, timelines, and risks in one place. Join the waitlist for early access at https://scale-your-impact.notion.site/27dd9c6ba679804b80a7ce439d56c91a?pvs=105 🧬 Stop second-guessing your CMC strategy. Get an investor-ready CMC roadmap in 2 weeks, before mistakes cost you $2M+ and 18 months of delays. Secure your spot at https://stan.store/SmartBiotech/p/dont-let-cmc-kill-your-funding-round Support the show

    21 min
  5. OCT 2

    194: Viral Vector CDMO Mastery: Singapore's Answer to Cell and Gene Therapy Supply Shortages with Lucas Chan - Part 2

    What if the future of affordable, life-changing cell and gene therapies comes down to one critical yet often overlooked factor: manufacturing efficiency? In advanced therapy medicinal products (ATMPs), groundbreaking science abounds, but the path to the clinic is still strewn with bottlenecks, especially when it comes to cost, complexity, and safety. While the promise is enormous, most therapies remain out of reach for many patients due to high cost of goods and logistical hurdles. What can actually break down these barriers and democratize access? In this episode, David Brühlmann welcomes Lucas Chan, celebrated Fellow of the Royal Society of Biology, advisor to Singapore's Ministry of Health, and a true pioneer in viral vector manufacturing. In Singapore, he founded CellVec Pte Ltd – APAC’s first regulatory accredited Viral Vector specialist CDMO. Lucas's leadership spans founding ventures in emerging markets to championing game-changing innovations in gene transfer, always with an eye toward efficiency, safety, and accessibility. Having returned “back to the bench” in collaboration with the National University of Singapore while launching his consultancy, Lucas brings both visionary perspective and hands-on experience to one of biotech’s toughest challenges. Here are three reasons why you need to listen to this episode: Efficiency is Everything: Lucas dissects how complex processes and outdated manufacturing paradigms are driving up the cost of cell and gene therapies and shares real-world advances, from transitioning viral vector production to stable producer cell lines to the emergence of non-viral gene transfer modalities, that are poised to rewrite the rulebook on scalability and affordability.Leadership Amid Complexity: Learn from Lucas’s top leadership advice drawn from his CSO and CDMO tenure: inspire teams by connecting every task to the larger mission. In a multidisciplinary, high-stakes environment, alignment and motivation aren’t just nice, they’re essential for innovation.Entrepreneurship and Community: Thinking of turning your biotech expertise into a startup? Lucas underscores the value of learning from others’ journeys, collaboration, and the insight that “it takes a village” when translating advanced therapies from bench to bedside, especially in emerging markets with unique affordability challenges.Want to transform your approach to cell and gene therapy manufacturing or just need inspiration to push your biotech project to the next level? Tune into this episode for practical insights, candid leadership lessons, and a renewed sense of what’s possible when we challenge the status quo together. Connect with Lucas Chan: LinkedIn: www.linkedin.com/in/lucaschangt Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call Preparing for your IND? We’re building a CMC Dashboard in Excel to help biotech founders track tasks, timelines, and risks in one place. Join the waitlist for early access at https://scale-your-impact.notion.site/27dd9c6ba679804b80a7ce439d56c91a?pvs=105 🧬 Stop second-guessing your CMC strategy. Our CMC strategy accelerator identifies critical roadmap gaps that could derail your timelines and gives you the clarity to build a submission package that regulators approve. Secure your spot at https://stan.store/SmartBiotech/p/derisk-cmc-development Support the show

    19 min
  6. SEP 30

    193: Viral Vector CDMO Mastery: Singapore's Answer to Cell and Gene Therapy Supply Shortages with Lucas Chan - Part 1

    Viral vectors are the backbone of cutting-edge cell and gene therapies, delivering life-altering treatments to patients with genetic diseases. But making these biological delivery vehicles is a high-wire act: unpredictable, complex, and fraught with hurdles that traditional biologics manufacturers have never faced. While the world races toward next-generation therapies, the challenge of producing viral vectors at clinical and commercial scale threatens to leave patients waiting on the sidelines. Our guest on the Smart Biotech Scientist Podcast is Lucas Chan, a molecular and cell biologist with over two decades of hands-on experience in cell and gene therapy development. From his formative research at Imperial College London, where he pioneered novel viral vector cell lines, to building the UK’s first GMP clinical viral vector core and later founding CellVec Pte Ltd Asia Pacific CDMO in Singapore, Lucas is the go-to architect for manufacturing viral vectors where infrastructure barely exists. Along the way, he’s faced and overcome challenges few others could imagine. Here are three reasons this episode is a must-listen: Viral Vectors Demystified: Lucas breaks down a common misconception: viral vectors aren’t malignant viruses, but genetically disarmed delivery vehicles that can’t revert or replicate, making them safe tools for gene therapy.Manufacturing Mayhem Made Manageable: Unlike monoclonal antibodies and other biologics, viral vectors (and other cell and gene therapies) are made in living cells, leading to a level of process unpredictability and complexity where “everything, everywhere, all at once” applies. Success hinges on scientific acumen and attention to even the smallest detail, from raw materials to equipment parameters, to ensure patient safety and product quality.Pioneering in Uncharted Territory: Moving from London to Singapore, Lucas faced not just technical but regulatory and logistical challenges to founding Asia-Pacific’s first CDMO dedicated to viral vectors. His advice: engage regulators early, leverage local biomanufacturing strengths, and build multidisciplinary teams to transfer and scale bioprocess know-how.Curious how viral vector manufacturing can be reimagined to unlock the full promise of cell and gene therapies? Listen to this episode and gain unique insights into the science, strategy, and sheer determination needed to bring advanced therapies out of the lab and into the clinic. Connect with Lucas Chan: LinkedIn: www.linkedin.com/in/lucaschangt Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call 🧬 Stop second-guessing your CMC strategy. Our CMC strategy accelerator identifies critical roadmap gaps that could derail your timelines and gives you the clarity to build a submission package that regulators approve. Secure your spot at https://stan.store/SmartBiotech/p/get-cmc-clarity-in-1-week--investor-ready Support the show

    29 min
  7. SEP 25

    192: Process Intensification Secrets: A Process Engineer's Decision Framework with Andreas Castan - Part 2

    Is continuous manufacturing delivering the transformative results everyone promised, or are you being sold an expensive solution to the wrong problem? While industry headlines tout revolutionary productivity gains, the economic reality behind continuous bioprocessing tells a more nuanced story that every process engineer needs to understand before making capital investment decisions. In this episode, host David Brühlmann continues his conversation with Andreas Castan, Strategic Technology and Business Development Leader at Cytiva, diving deep into the hard economics and operational realities of next-generation manufacturing strategies. Andreas brings over 25 years of bioprocess expertise from upstream innovation to cGMP manufacturing scale-up. Here are three critical takeaways from this conversation: Continuous vs Fed-Batch Economics Are Closer Than Expected: Andreas reveals real process economic modeling data showing that while continuous reduces capital costs through smaller bioreactors and facilities, higher media consumption (20-25% of COGS) and operational complexity often balance out the savings. The deciding factor isn't technology elegance but your specific production volume and pipeline needs.Regulatory Approval Isn't Easier Despite FDA Support: Even with regulatory enthusiasm for continuous processing, QA teams still demand the same fundamentals: traceability, batch definition, viral clearance validation, and process characterization. The technology choice should be driven by your business case, not regulatory preferences.Sustainability Benefits Are Modest: Contrary to industry hype, Andreas shares findings showing continuous manufacturing delivers only 20% carbon footprint reduction compared to optimized fed-batch. Real environmental gains come from HVAC efficiency and smaller cleanroom footprints, not inherent process advantages.Ready to cut through the marketing noise and make data-driven manufacturing decisions? This conversation delivers the unvarnished truth about when continuous processing creates real value and when intensified fed-batch might be your smartest investment. Connect with Andreas Castan: LinkedIn: www.linkedin.com/in/andreas-castan-91570b1 Cytiva landing page: Process intensification Online tool: Process intensifier Next step: Book a 20-minute call to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call 🧬 Stop second-guessing your CMC strategy. Our CMC strategy accelerator identifies critical roadmap gaps that could derail your timelines and gives you the clarity to build a submission package that regulators approve. Secure your spot at https://stan.store/SmartBiotech/p/get-cmc-clarity-in-1-week--investor-ready Support the show

    20 min
  8. SEP 23

    191: Process Intensification Secrets: A Process Engineer's Decision Framework with Andreas Castan - Part 1

    What if process intensification could transform your bioprocessing economics without the complexity most engineers fear? Getting 3x productivity gains and 30-150% titer increases once seemed reserved for Big Pharma's endless R&D budgets, but a strategic approach to technology selection is making these results achievable for companies of any size. In this episode, David Brühlmann speaks with Andreas Castan, a bioprocess veteran with over 25 years of industry experience who provides leadership and support to Cytiva's bioprocess business. Andreas brings deep expertise from directing upstream development at Swedish Orphan Biovitrum and extensive work in expression systems, process development, scale-up, and cGMP manufacturing across multiple therapeutic modalities. Why tune in? Here's your process engineer's roadmap: Process Intensification Economics Decoded: Andreas reveals the cost-benefit reality behind continuous vs fed-batch manufacturing, including real process economic modeling data showing why the differences aren't as dramatic as you'd expect and what factors actually drive your business case.Low-Hanging Fruit That Delivers: Skip the overhyped AI solutions. Andreas shares the strategic fundamentals that work: high-producing cell line development, N-1 perfusion for rapid productivity gains, and smart bioreactor turndown strategies that eliminate process steps without adding complexity.Decision Framework for Technology Selection: Learn when continuous processing makes economic sense (and when it doesn't), how media costs impact your COGS analysis, and why understanding your bottlenecks, not following industry trends, should drive your intensification strategy.Industry Insider Strategies: Get the inside track on what AstraZeneca, Sanofi, Merck, Lonza, and Takeda are actually implementing, plus Andreas's perspective on why human expertise and mechanistic insights still outweigh AI in real-world process decisions.Ready to make smarter technology investments and achieve measurable productivity gains? This isn't theory. It's a practical guide to process intensification economics that you can apply whether you're preparing for Phase I or scaling for commercial manufacturing. Connect with Andreas Castan: LinkedIn: www.linkedin.com/in/andreas-castan-91570b1 Cytiva landing page: Process intensification Online tool: Process intensifier Next step: 🧬 Stop second-guessing your CMC strategy before investor meetings. Our 1-Week CMC Assessment reveals your roadmap gaps and transforms uncertain founders into confident presenters who ace investor meetings. Secure your assessment at https://stan.store/SmartBiotech/p/get-cmc-clarity-in-1-week--investor-ready De-risk CMC development and get decision-making guidance with a new AI platform that transforms CMC overwhelm into predictable development success (launching early 2026). Join the waitlist here: 🧬 Stop second-guessing your CMC strategy. Our fast-track CMC roadmap assessment identifies critical gaps that could derail your timelines and gives you the clarity to build a submission package that regulators approve. Secure your assessment at https://stan.store/SmartBiotech/p/get-cmc-clarity-in-1-week--investor-ready Support the show

    21 min
5
out of 5
9 Ratings

About

The Go-to Podcast for Biotech Scientists Who Want to Master Biopharma CMC Development and Biomanufacturing. **TOP 10 LIFE SCIENCES PODCAST** Are you ready to simplify bioprocess development and scale with confidence to reduce time to market? Are you feeling overwhelmed by the complexity and guesswork of biologics development and biomanufacturing? Do you wish you had more time to enjoy the beauty of science, without worrying about failing your cell culture process development and commercialization? There's a way to simplify and streamline so you can remove complexity, skip trials and errors, deliver your groundbreaking therapy to clinics and market without delay, and still enjoy every single step. I'm David Brühlmann, a biotech entrepreneur and strategic advisor who partners with C-level biopharma leaders to tackle one of our industry's biggest challenges: reducing manufacturing costs to make lifesaving therapies accessible to more patients worldwide. Through engaging conversations with industry pioneers and practical insights from the trenches, this podcast tackles the critical challenges in bioprocess CMC development and manufacturing of recombinant proteins and cell and gene therapy products. We cut through the complexity so you can: Master bioprocess development with confidence and clarity Excel at scale-up and manufacturing of biologics Transform your innovative therapy and manufacturing technology into market-ready solutions faster Optimize manufacturing costs without compromising quality Make data-driven decisions that reduce the risk of failure I can’t wait to help you do biotech the smart way. Grab a cup of coffee and your favorite notebook and pen. Now is the time to take your bioprocessing game to the next level. Ready to transform your biomanufacturing journey? Let's dive in! Next Steps: Book a free call to reduce biomanufacturing costs and make lifesaving therapies more accessible: https://bruehlmann-consulting.com/call 🧬 Ready to accelerate your IND timeline? Get the proven CMC Dashboard that's guided successful mAb programs from chaos to submission: https://stan.store/SmartBiotech/p/cmc-dashboard-for-biotech-founders Accelerate biologics development with expert guidance: https://bruehlmann-consulting.com Visit the Website: https://smartbiotechscientist.com Email us: hello@bruehlmann-consulting.com

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