Application of Hybrid Bioreactor Models as Digital Shadows in Commercial Manufacturing

Nian Liu 
Sanofi

Abstract 

Advanced hybrid bioreactor models offer significant value in commercial manufacturing by providing manufacturers with in-depth visibility and insights into batch progression. In this talk, we will present the end-to-end deployment of hybrid models as digital shadows, covering model development across multiple scales, data connectivity, and deployment during Process Performance Qualification (PPQ) campaigns.

We will demonstrate how we can successfully predict, in real-time, remaining batch trajectories as well as end-of-run titer and product quality through a combination of hybrid modeling and state estimation. This work establishes a framework for digital shadow implementation and afoundation for future closed-loop digital twins.

Nian Liu 

Nian Liu 

Principal Scientist

Nian Liu is a Principal Scientist within the CMC Process Modeling team at Sanofi, where he is responsible for developing various mechanistic models and AI-driven systems for applications in both upstream and downstream biologics development. He previously earned his Ph.D. degree in Chemical Engineering at MIT.

Prior to joining Sanofi as a data scientist, Nian also gained extensive hands-on experience in process and media development at several cell therapy companies, bridging experimental process understanding with advanced modeling to drive innovation.

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