How do you transform hybrid model digital twins from promising lab concepts into commercial bioprocessing game-changers that actually deliver ROI?

As biotech companies race to implement Industry 4.0 technologies, the critical challenge isn't just developing sophisticated hybrid models - it's deploying them strategically to create user-friendly, cost-effective solutions that genuinely accelerate your path to commercial bioprocessing success.

In Part 2 of this essential conversation, David Brühlmann continues his deep dive with Krist Gernaey, Professor of Industrial Fermentation Technology at the Technical University of Denmark. Krist reveals the strategic framework for moving beyond digital twin hype to build hybrid modeling capabilities that scale from lab validation to commercial manufacturing reality.

Three Strategic Insights for Commercial Implementation:

• Digital Twins That Deliver Business Value: Krist cuts through the marketing buzz to define what makes digital twins commercially viable - revealing why true value comes from two-way data exchange and predictive capabilities, not just virtual process copies. Learn the validation strategies that separate successful implementations from expensive pilot projects.
• Modular Strategy Over Technology Complexity: Forget the "silver bullet" mentality. Krist advocates for strategic building blocks: start with site comparisons and predictive maintenance, then systematically add hybrid modeling complexity as your organization develops the technical capacity and team skills for sustainable commercial success.
• User-Centric Models for Operational Excellence: The biggest commercial wins aren't always about optimizing yields - they're about creating transparency, robust documentation, and operator-friendly tools that reduce complexity rather than adding it. Discover how to design hybrid model digital twins that empower your manufacturing teams instead of overwhelming them.

Ready to develop a strategic roadmap for implementing hybrid model digital twins that drive commercial bioprocessing success? Tune in for Krist's proven framework for avoiding "cauliflower complexity" while building sustainable digital transformation capabilities that scale.

Connect with Krist Gernaey:

LinkedIn: www.linkedin.com/in/krist-gernaey-591748

Website: www.orbit.dtu.dk/en/persons/krist-v-gernaey

If you’re intrigued by the evolving frontier of bioprocessing, don’t miss these enlightening episodes:

• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli
• Episodes 153-154: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos
• Episodes 05-06: Hybrid Modeling: The Key to Smarter Bioprocessing with Michael Sokolov

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 https://stan.store/SmartBiotech

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Are you struggling to bridge the gap between lab-scale models and commercial bioprocessing reality? For many biotech innovators, the promise of digital twins meets harsh industrial constraints - where hybrid models that excel in controlled lab environments must prove themselves in the complexity of large-scale manufacturing.

This week on the Smart Biotech Scientist Podcast, host David Brühlmann welcomes Krist Gernaey, Professor of Industrial Fermentation Technology at the Technical University of Denmark. With expertise spanning measurement technology development and two decades pioneering hybrid model digital twins for bioprocess applications, Krist reveals the critical gap between digitalization hype and industrial implementation reality.

Here are three key reasons this episode will level up your hybrid modelling and digital twin approaches.

• From Data Overload to Intelligent Control: Raw sensor data means nothing without the right models to interpret it. Krist demonstrates how hybrid model digital twins convert complex bioprocess measurements into actionable control strategies - showing why sophisticated algorithms need simple, robust sensors to succeed at commercial scale.
• From Individual Genius to Team Implementation: The most elegant digital twin fails without operator buy-in. Krist shares why successful commercial bioprocessing depends on bridging academic innovation with frontline manufacturing expertise - revealing the human factors that make or break advanced modeling initiatives.
• From Lab Perfection to Commercial Pragmatism: Discover why the most promising hybrid modeling approaches must balance mechanistic understanding with data-driven adaptation. Krist provides a reality check on electrochemical sensors, validation challenges, and the strategic decisions that determine whether digital twins deliver commercial value or remain expensive experiments.

Ready to master the art of scaling hybrid model digital twins from promising lab tools to commercial bioprocessing game-changers? Tune in to discover Krist Gernaey's battle-tested strategies for navigating the complex journey from academic innovation to industrial impact.

Connect with Krist Gernaey:

LinkedIn: www.linkedin.com/in/krist-gernaey-591748

Website: www.orbit.dtu.dk/en/persons/krist-v-gernaey

If you’re intrigued by the evolving frontier of bioprocessing, don’t miss these enlightening episodes:

• Episodes 85-86: Bioprocess 4.0: Integrated Continuous Biomanufacturing with Massimo Morbidelli
• Episodes 153-154: The Future of Bioprocessing: Industry 4.0, Digital Twins, and Continuous Manufacturing Strategies with Tiago Matos
• Episodes 05-06: Hybrid Modeling: The Key to Smarter Bioprocessing with Michael Sokolov

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 https://stan.store/SmartBiotech

Support the show

Downstream processing remains one of the most complex and critical steps in biomanufacturing, especially as new therapeutic modalities like cell and gene therapies push current technologies to their limits. The industry faces ongoing pressure to innovate, reduce costs, and improve efficiency, while still ensuring robust and reliable results.

In this practical, energetic episode, host David Brühlmann welcomes Scott Wheelwright, Chairman, CTO and Co-Founder of BioChromatographix International (BCI). With a career spanning continents - Asia, Europe, and North America - Scott's perspective is forged from hands-on manufacturing, technology transfer, and building high-growth companies from scratch. He’s not just innovating the science behind chromatography; he’s lived the manufacturing realities, spanning everything from precision antibodies to complex gene therapies, and now leads a team solving the tough purification puzzles holding progress back.

Here are three reasons why this episode is a must-listen:

• Continuous Innovation in Chromatography: Despite a hundred-year legacy, chromatography still holds tremendous untapped potential, especially with new materials and continuous processing, as Scott highlighted with real examples from gene and cell therapy applications.
• Bridging Lab to Market Needs Customer Focus: Getting new technology into commercial use requires not just technical innovation, but deep user engagement, robust feedback loops, and iterative improvement, plus ongoing education to help users understand new benefits.
• Embrace Experimentation and Global Collaboration: Whether building companies in Asia, Europe, or the U.S., Scott reminds us that learning from failure, being open to international collaboration, and not being afraid to try new things are essential for long-term growth (and enjoying the biotech journey along the way!).

If you’re passionate about downstream processing, tech innovation, or just want to hear inspiring leadership lessons, check out the full episode and connect with Scott Wheelwright or visit the company’s website to follow his team’s advancements.

Connect with Scott Wheelwright:

LinkedIn: www.linkedin.com/in/scottmwheelwright

Website: www.biochromatographix.com

Curious about chromatography? Tune in to hear what our previous guests had to say!

• Episodes 119-120: Innovating Protein Purification Using Synthetic Organelles and AI with Haotian Guo
• Episodes 61-62: Magnetic Bead Technology: The New Era in Downstream Processing with Nils Brechmann
• Episodes 37-38: How to Master Downstream: A Deep Dive Into Bioprocessing Purification with Wei Zhang

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 https://stan.store/SmartBiotech

Support the show