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Capacity planning for batch and perfusion bioprocesses across multiple biopharmaceutical facilities

Siganporia, CC; Ghosh, S; Daszkowski, T; Papageorgiou, LG; Farid, SS; (2014) Capacity planning for batch and perfusion bioprocesses across multiple biopharmaceutical facilities. Biotechnology Progress , 30 (3) pp. 594-606. 10.1002/btpr.1860. Green open access

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Abstract

Production planning for biopharmaceutical portfolios becomes more complex when products switch between fed-batch and continuous perfusion culture processes. This paper describes the development of a discrete-time mixed integer linear programming (MILP) model to optimise capacity plans for multiple biopharmaceutical products, with either batch or perfusion bioprocesses, across multiple facilities to meet quarterly demands. The model comprised specific features to account for products with fed-batch or perfusion culture processes such as sequence-dependent changeover times, continuous culture constraints, and decoupled upstream and downstream operations that permit independent scheduling of each. Strategic inventory levels were accounted for by applying cost penalties when they were not met. A rolling time horizon methodology was utilised in conjunction with the MILP model and was shown to obtain solutions with greater optimality in less computational time than the full-scale model. The model was applied to an industrial case study to illustrate how the framework aids decisions regarding outsourcing capacity to third party manufacturers or building new facilities. The impact of variations on key parameters such as demand or titres on the optimal production plans and costs was captured. The analysis identified the critical ratio of in-house:CMO manufacturing costs that led the optimisation results to favour building a future facility over using a CMO. The tool predicted that if titres were higher than expected then the optimal solution would allocate more production to in-house facilities, where manufacturing costs were lower. Utilisation graphs indicated when capacity expansion should be considered. © 2013 American Institute of Chemical Engineers Biotechnol. Prog., 2013.

Type: Article
Title: Capacity planning for batch and perfusion bioprocesses across multiple biopharmaceutical facilities
Open access status: An open access version is available from UCL Discovery
DOI: 10.1002/btpr.1860
Publisher version: http://dx.doi.org/10.1002/btpr.1860
Language: English
Additional information: © 2014 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers This is an open access article under the terms of the Creative Commons Attribution License, which permits use, distribution and reproduction in any medium, provided the original work is properly cited.
Keywords: Business decision-making, capacity planning, mixed integer linear programming (MILP), rolling time horizon, scheduling
UCL classification: UCL
UCL > Provost and Vice Provost Offices > UCL BEAMS
UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science
UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Biochemical Engineering
UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Chemical Engineering
URI: https://discovery.ucl.ac.uk/id/eprint/1425770
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