Smart Biotech Scientist | The CMC and Bioprocessing Podcast for Process Development and Manufacturing Leaders

From lab curiosity to commercial reality. Here's what happens when moss meets the brutal economics of bioprocessing.

In Part 1, you've heard the science behind moss-based protein production. Now comes the real test: Can it survive the gauntlet of regulatory scrutiny, cost pressures, and manufacturing scale-up that crushes most biotech innovations?

In Part 2 of this groundbreaking conversation, David Brühlmann and Andreas Schaaf, Managing Director and CSO of Eleva, dive into the nuts and bolts of what it actually takes to commercialize a revolutionary production platform. Andreas doesn't just theorize—he's lived through 15+ years of transforming Eleva from startup concept to clinical-stage reality, navigating every regulatory hurdle and economic challenge along the way.

Three game-changing advantages that caught our attention:

• Process Robustness That Actually Works: While CHO cells throw tantrums over minor parameter shifts, moss maintains consistent product quality even when your bioprocess isn't behaving perfectly; a lifeline for manufacturing teams dealing with real-world variability.
• Economics That Make CFOs Smile: Forget expensive viral filtration steps and costly human pathogen testing. Moss's plant heritage eliminates these animal-system burdens, directly impacting your bottom line in ways that matter.
• Operational Simplicity: Variability in process ingredients and streamlined cell banking contribute to long-term cost and operational efficiencies that compound over time.

Andreas shares hard-won insights about what it really takes to challenge entrenched bioprocessing orthodoxy, including the regulatory conversations, the economic realities, and his advice for scientists brave enough to pursue game-changing innovations.

Ready to understand how disruptive biotechnology actually makes it from bench to bedside?

Connect with Andreas Schaaf:

LinkedIn: www.linkedin.com/in/andreas-schaaf-b3797716

Website: www.elevabiologics.com

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

What if the future of "impossible" protein therapeutics is hiding in your backyard?

For decades, CHO cells have ruled the biotech kingdom as the undisputed champions of complex protein production. But here's the uncomfortable truth: countless breakthrough therapies are gathering dust on laboratory shelves—not because the science failed, but because traditional hosts can’t produce them.

Enter moss. Yes, moss. That humble green organism clinging to rocks and trees might just be the biotech industry's best-kept secret.

In this eye-opening episode, David Brühlmann sits down with Andreas Schaaf, Managing Director and CSO of Eleva, who's spent over 20 years turning the "impossible" into reality. Andreas didn't just stumble upon moss; he co-developed Eleva's revolutionary moss-based platform from wild concept to commercial-scale game-changer, propelling the company into clinical trials.

Here are three reasons why this episode is worth listening to:

• Moss as a Game Changer: More than a plant, moss is a higher eukaryote with mammalian-like protein production, including post-translational modifications and human-compatible glycosylation.
• Overcoming Bioprocessing Barriers: CHO cells are the industry gold standard, especially for monoclonal antibodies. But what about the therapeutic proteins that CHO can’t handle? Many promising candidates end up shelved—not because the science isn't sound, but because existing production platforms hit their limits.
• Bioprocessing, Simplified: Moss grows in standard bioreactors using familiar workflows—just with a whole organism instead of suspended cells.

Curious about how plant-based systems could solve your protein production challenges? Dive into this episode to discover how moss could revolutionize your approach to challenging proteins; and let us know about your own production hurdles.

Connect with Andreas Schaaf:

LinkedIn: www.linkedin.com/in/andreas-schaaf-b3797716

Website: www.elevabiologics.com

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

The world of cell therapy is changing rapidly, with revolutionary advancements in cryopreservation and bioprocessing protocols leading the way. In a recent episode of the Smart Biotech Scientist Podcast, host David Brühlmann sat down with Jeffrey Allen, Chairman and CEO of Evia Bio, to dive deep into the “how” of implementing cutting-edge techniques in the lab and the strategic mindset needed to move therapies from concept to clinic successfully.

Jeffrey Allen is a passionate leader with a diverse background in shaping strategy, building high-performing teams, and driving exceptional results across public and private equity-backed organizations. With extensive C-level and international experience in the life sciences sector, Jeffrey has a proven track record of transforming performance and delivering profitable growth in various market environments.

Here are three key takeaways for anyone passionate about advancing biotech:

• The four-step audit: bridging best practices and real-world results: Depending on client needs, the audit is performed either at the client’s laboratory or at Evia Bio’s own facility, ensuring real-world practices are scrutinized and optimized.
• Protocols matter and so does execution: Even the best-written protocols can falter if not followed meticulously. Regular process audits, sometimes conducted onsite by external partners, help identify “protocol creep” and ensure teams are consistently implementing best practices.
• Culture fuels innovation: Jeffrey’s leadership advice resonated-aligning on strategy, fostering unified company culture, and surrounding yourself with talented people accelerates growth. Passion for the mission, combined with a strong, diverse team, can deliver both exceptional results and lasting employee engagement.

Curious how these insights could save you months of frustration and millions in development costs? Tune in to the full episode, or get in touch to discuss how process optimization can empower your cell therapy journey!

Connect with Jeffrey Allen:

LinkedIn: www.linkedin.com/in/jeffreydallen2

Website: www.eviabio.com

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Support the show

If you’ve ever worked in a cell therapy lab or handled biologics, you’ve probably experienced the pitfalls of cryopreservation. We’ve all mourned the loss of precious samples after a freeze-thaw cycle gone wrong or watched viability figures plummet, wondering where it all went awry.

In this episode of The Smart Biotech Scientist Podcast, Jeffrey Allen, Chairman and CEO of Evia Bio, shares how nature-inspired solutions are changing the cell preservation game. With a background spanning finance, operations, and leadership across the biotech landscape, Jeffrey brings a unique perspective on bridging science and practical manufacturing needs.

Inspired by the survival strategies of Minnesota’s frozen forests, a new wave of biotech innovation is transforming the way we freeze, store, and ship life-saving cells for therapies - and it all starts with a better understanding of nature.

Here are the top three takeaways from this podcast episode:

• Cryopreservation shouldn’t be an afterthought: Building optimal cryopreservation strategies into your process development from day one can avoid costly setbacks and delays.
• Beyond cell viability - function matters: It’s not just about how many cells survive the freeze/thaw cycle, but whether those cells remain fully functional. Evia Bio’s new DMSO-free formulations are delivering >85% recovery on MSCs without compromising cell function.
• One size doesn't fit all: Every cell type has unique needs for freezing, thawing, and formulation. Leveraging tailored algorithms and customized protocols can drastically improve yield and reproducibility, potentially reducing the need for costly overfilling in manufacturing.

If you’ve ever lost precious cell samples to a freeze-thaw mishap or questioned why you’re stuck with outdated, toxic cryopreservation methods, this episode is for you!

Connect with Jeffrey Allen:

LinkedIn: www.linkedin.com/in/jeffreydallen2

Website: www.eviabio.com

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

In this concluding episode of our deep dive into miniaturized perfusion systems, we tackle the most challenging aspect: implementing meaningful process analytical technology (PAT) at microscale while keeping costs realistic for high-throughput applications.

Tom Valentin, group leader at CSEM for Automated Sample Handling, continues sharing CSEM's pioneering work in automated sample handling, revealing both the breakthrough opportunities and stubborn technical barriers that define the current state of small-scale perfusion development.

Critical insights you'll gain from this episode:

• The PAT miniaturization challenge is about more than size: While optical density sensors work reasonably well for microbial cultures, mammalian cell applications demand more sophisticated solutions. Tom explains why viable cell density remains the "holy grail"—and how promising technologies from companies like IMEC and Inspec are pushing the boundaries, though cost-effective 96-well implementation remains elusive
• Smart compromises can unlock practical solutions: Tom reveals why the industry may need to accept hybrid approaches—real-time pH and DO monitoring combined with once-daily viable cell density sampling. He also explains the unique challenges of sensor positioning in shaking deep-well plates where liquid dynamics create measurement complexities
• Partnership models that actually work for biotech innovation: Beyond the technical discussion, Tom outlines CSEM's proven collaboration approaches, including how Innoswiss funding can provide 50% cost reduction for development projects and why their 70% proposal success rate makes them an attractive R&D partner for both startups and established pharma companies

Discover how bioprocessing is evolving - from high-throughput screening to digital twins and continuous manufacturing- in these expert-led episodes.

• Episode 155: From Process Bottlenecks to Seamless Production: How Continuous Bioprocessing Changes Everything
• Episodes 153-154: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos
• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli
• Episodes 73-74: Bead-Based Assays: The Power of High-Throughput Screening with Sebastian Giehring

Connect with Tom Valentin:

LinkedIn: www.linkedin.com/in/tom-valentin-5bb9091b

Website: www.csem.ch/en

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

In bioprocess development, the ability to rapidly screen conditions and predict scale-up performance can mean the difference between a successful therapy launch and costly delays. Today's Smart Biotech Scientist episode features Tom Valentin from CSEM, who's pioneering revolutionary approaches to miniaturized perfusion systems that could transform how we develop biologics.

Tom is a group leader at CSEM for Automated Sample Handling within the Life Sciences and Industry 4.0 business unit. As a mechanical and biomedical engineer, he brings a unique cross-disciplinary perspective to solving bioprocessing's most challenging miniaturization problems.

What makes this conversation essential listening:

• 96-deep-well plates are revolutionizing perfusion development: Tom reveals how CSEM's innovative fluidic lids enable continuous medium exchange in 300-microliter volumes, potentially allowing up to 96 parallel perfusion experiments with automated liquid handlers and shaker incubators
• Three critical barriers still need solving: Despite the promise, Tom identifies the key technical challenges that must be overcome: ultra-low flow rate liquid handling (imagine exchanging 300 μL over 24 hours), effective cell retention in miniaturized systems, and cost-effective real-time biomonitoring that fits within well plate constraints
• The future of process development is automated and intelligent: From pressure-over-liquid systems to advanced sensor integration, Tom outlines how companies can achieve near-autonomous perfusion screening—but warns that current sensing limitations mean viable cell density monitoring remains the "holy grail" of small-scale perfusion

This isn't just about smaller equipment—it's about fundamentally changing how we approach process development. If you're working in cell culture optimization, process scale-up, or bioprocess automation, Tom's insights reveal both the tremendous opportunities and practical realities of implementing next-generation perfusion systems.

For biotech professionals, staying ahead means embracing these high-throughput, data-rich models, allowing smarter, faster, and more predictive process development for the therapies of tomorrow.

Discover how bioprocessing is evolving - from high-throughput screening to digital twins and continuous manufacturing- in these expert-led episodes.

• Episode 155: From Process Bottlenecks to Seamless Production: How Continuous Bioprocessing Changes Everything
• Episodes 153-154: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos
• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli
• Episodes 73-74: Bead-Based Assays: The Power of High-Throughput Screening with Sebastian Giehring

Connect with Tom Valentin:

LinkedIn: www.linkedin.com/in/tom-valentin-5bb9091b

Website: www.csem.ch/en

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

In this concluding episode of our series on revolutionary endotoxin detection, we continue our conversation with Anika Hoffmann about transitioning from theory to practice in the quest for more reliable, sustainable testing methods. Anika is a postdoctoral researcher in analytical chemistry at HES-SO Valais-Wallis, Switzerland.

Having established why traditional LAL testing falls short in Part 1, we now explore how Anika's innovative KDO-based chemical analytical approach compares in real-world applications:

• Greater accuracy you can trust: The new method delivers impressive 5-10% coefficient variation (compared to LAL's 25%), works across broader pH and formulation conditions, but is still working toward the sensitivity targets needed for all pharmaceutical applications
• Clear path to regulatory acceptance: Anika outlines how companies can validate alternative methods against established standards like LAL, recombinant Factor C, or monocyte activation tests to gain approval from authorities
• Sustainable testing strategy: Health authorities and customers are increasingly demanding sustainable alternatives as horseshoe crab populations decline while testing demand rises—adopt ethical, animal-free methods now before they become an industry requirement

Most excitingly, Anika reveals her entrepreneurial journey from accidental discovery to startup founder. Her passion for solving this critical industry challenge exemplifies how scientists can transform technical innovations into practical solutions that benefit both industry and the environment.

Whether you're a bioprocess scientist struggling with endotoxin testing, a quality assurance professional seeking more reliable methods, or someone interested in sustainable alternatives to animal-based testing, this episode provides a clear path toward a future where patient safety doesn't rely on horseshoe crab blood.

Listen now to discover how you can implement smarter endotoxin testing at your organization – and reach out to Anika via the links in our show notes if you want to be among the first to access this groundbreaking technology.

Connect with Anika Hoffmann:

LinkedIn: www.linkedin.com/in/anika-hoffmann-652ab0196/

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Support the show

In biopharmaceutical manufacturing, endotoxins represent a silent but deadly threat – bacterial fragments capable of triggering severe immune responses at picogram levels, potentially leading to septic shock, organ failure, or even death in patients.

In this eye-opening first episode, we speak with Anika Hoffmann, a postdoctoral researcher in analytical chemistry at HES-SO Valais-Wallis, Switzerland, who's challenging the decades-old status quo of endotoxin testing. For nearly 50 years, the industry has relied on horseshoe crab blood (LAL assay) despite its significant limitations and sustainability concerns.

Anika reveals the troubling truth about traditional testing methods:

• The LAL reliability problem: With acceptable recovery rates ranging from 50-200% and high variability, can we truly trust our current methods?
• The "low endotoxin recovery" phenomenon: How common pharmaceutical ingredients can mask dangerous endotoxins, creating false negatives
• The horseshoe crab sustainability crisis: Rising testing demand threatens declining horseshoe crab populations

Most importantly, Anika introduces her groundbreaking alternative: a chemical analytical method targeting KDO, a unique sugar molecule present in all endotoxins. This approach eliminates reliance on enzymes or animal products while providing more consistent results across different pharmaceutical formulations.

With regulatory limits as strict as 0.25 EU/mL for water for injection, reliable detection isn't just a quality issue – it's a patient safety imperative. If you're developing biologics, managing bioprocess quality, or navigating regulatory compliance, this episode reveals why rethinking endotoxin testing could be your most important decision.

Listen to Part 1 to discover why smarter endotoxin testing is possible without relying on horseshoe crab blood, and stay tuned for Part 2 where we'll explore the practical implementation of this revolutionary approach.

Connect with Anika Hoffmann:

LinkedIn: www.linkedin.com/in/anika-hoffmann-652ab0196/

Email: [email protected]

Next step:

Book a free consultation to help you get started on any questions you may have about bioprocessing analytics: https://bruehlmann-consulting.com/call

Develop bioprocessing technologies better, faster, at a fraction of the cost with our 1:1 Strategy Call: The quickest and easiest way to excel biotech technology development. Book your call at www.bruehlmann-consulting.com/call/

Support the show

The world of biologics manufacturing is undergoing a major transformation. Once dominated by traditional batch processes, the industry is now experiencing a marked shift toward continuous bioprocessing.

But as companies contemplate this transition, two questions dominate strategic discussions: Will regulators accept continuous manufacturing? And, perhaps more pressingly, Does the business case justify making the switch?

In this podcast episode of the Smart Biotech Scientist Podcast, David Brühlmann dives into these pivotal topics - drawing insights from real-world case studies, regulatory updates, and economic analyses.

Top three takeaways:

• Regulators Are On Board: The FDA, EMA, and global agencies now actively support continuous processing when robust controls and monitoring are in place.
• Real Economic Wins: Cost of goods reductions of up to 35% are possible at certain production scales, with much smaller facilities and lower risk of batch failure.
• Hybrid & Phased Approaches Work: Companies are finding success by first investing in enabling technologies and gradually transitioning, rather than making sudden changes.

Continuous bioprocessing is no longer an experimental promise - it’s an evolving standard. With regulatory bodies championing the shift, real-world implementations proving technical and economic viability, and strong financial incentives for the right manufacturers, the transition becomes not a question of “if,” but “when.”

Curious how continuous manufacturing can fit into your strategy? Listen to this episode and share your thoughts or questions!

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

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show

In this episode of the Smart Biotech Scientist Podcast, host David Brühlmann dives into continuous bioprocessing - a major shift in biologics manufacturing that's turning traditional batch processes into streamlined, real-time operations.

Imagine running your biologics process non-stop for 30 days, with smart monitoring and smaller, more efficient systems replacing massive reactors. It’s not just possible - it’s already happening across the industry, from Amgen’s 80% smaller facility to Sanofi’s modular "Factory of the Future."

David explores how companies - big and small - are increasing productivity, cutting costs, and reducing waste through continuous strategies. You'll also hear about enabling technologies, phased implementation approaches, and the challenges teams are navigating as they make the shift.

Top 3 Takeaways:

• Efficiency & Cost Savings Are Real: Amgen’s results speak volumes: 80% smaller footprint, faster deployment, and cost reductions of over 60% per gram of protein.
• It’s Not Just for Big Pharma: Small and mid-sized biotechs are embracing continuous processes to stay competitive - gaining speed, flexibility, and lowering production costs without massive infrastructure.
• You Don’t Have to Go All In: Challenges like cost, complexity, and workforce readiness exist - but many companies are succeeding with hybrid models, applying continuous techniques step-by-step.

What’s your take on continuous manufacturing? Tune in, share your thoughts, and join the conversation about the future of biotech production.

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

Free 5-day email course, The CMC Failure Chain: the five recurring CMC mistakes that put your promising program at risk → Get it here

Support the show