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How Digital Twins are Shaping the Future of Continuous Bioprocessing with Resilience and Siemens

Resilience is thrilled to participate in a joint webinar, “How Digital Twins are Shaping the Future of Continuous Bioprocessing with Resilience and Siemens,” on Wednesday, March 1, 2023, at 9:00 AM ET. 
Register for this informative 30-minute webinar here. 


- The digital twin modeling framework 
- Resilience overview and the continuous manufacturing process capabilities at Resilience 
- The steps taken to develop the integrated and continuous biomanufacturing (ICB) digital twin with Siemens gPROMS Formulated Products 
- Description and results of both single unit operation models and the full integrated end-to-end model 
- Case study on the impact of expected disturbances, deviations, and uncertainties on product quality 


Resilience is a first-of-its-kind manufacturing and technology company dedicated to broadening access to complex medicines and protecting biopharmaceutical supply chains against disruption. As a part of this vision, Resilience is developing an advanced end-to-end continuous drug substance manufacturing platform for biological molecules. To increase robustness, facilitate in silico process characterization, and enable an efficient process control strategy, we are developing a process digital twin of an integrated and continuous biomanufacturing (ICB) process at Resilience.  

The ICB digital twin uses Resilience advanced computational modeling framework together with a data-driven and mechanistic modeling approaches. Resilience believes the digital twin will be transformational in bringing significant value across process lifecycle and will be used to achieve optimal operating conditions with reduced amount of experimentation to expand process knowledge. 

Described herein are the steps for the development of the ICB digital twin model. The individual unit operation process models were built separately and then integrated into an end-to-end flowsheet simulation.  The model is being used to determine the impact of expected disturbances, deviations, and uncertainties on product quality. The goal is to use residence time distribution analysis to identify the duration of product diversion in response to the deviation, and allow product impacted by disturbance to be diverted without impacting the reminder of the batch. 

The ICB digital twin will enable us to characterize and build a robust process control strategy with fewer physical experiments, reduced risk, and fewer pilot trials. It will help us to successfully predict process performance and product quality in real time and enable us to do the virtual exploration of a process design space facilitating data-driven science- and risk-based implementation of the integrated continuous biomanufacturing (ICB) process at Resilience. 

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Speaker Bio  

Rui Wheaton is a modeling & simulation scientist, and currently leading the process economics and process system modeling program at Resilience.  

Rui has a wealth of experience in process engineering, computational fluid dynamics (CFD), and mechanistic modeling, and has used these tools for process performance and comparability evaluation, root cause investigation, and process improvement. 

Rui received her PhD in Chemical Engineering from Worcester Polytechnic Institute. Prior to joining Resilience, she has worked in Process Engineering roles at Bristol Myers Squibb and Praxair and has applied her expertise to support process development, scale-up, and troubleshooting of commercial processes.