Off Script: A Pharma Manufacturing Podcast

As municipal water utilities increasingly shift from free chlorine to chloramine disinfection strategies, pharmaceutical manufacturers are facing new challenges in maintaining consistent, high-purity water systems. While chloramines provide utilities with longer-lasting residual disinfection and reduced formation of regulated byproducts, they also introduce operational risks inside pharmaceutical facilities. As a result, manufacturers are reassessing traditional chloramine removal approaches and exploring more proactive treatment strategies that improve resiliency, monitoring, and long-term operational efficiency.

 

In this episode of Off Script, sponsored by Trojan Technologies, we spoke with Wayne Lem, global applications manager at Trojan Technologies, about the evolving role of UV technology in pharmaceutical water treatment systems. The conversation explores how chloramine shifts at the municipal level are impacting pharmaceutical manufacturing operations, the limitations of traditional approaches like catalytic carbon and reducing chemicals, and how UV-based chloramine destruction can help facilities improve process reliability while reducing maintenance and chemical dependency. Lem also discusses the operational and economic considerations behind UV adoption, the importance of continuous monitoring and validation in regulated environments, and why hybrid, multi-barrier treatment strategies are becoming increasingly important as manufacturers modernize water infrastructure.

Amid increasing complexity in the drug development landscape, CDMOs are exploring new ways to streamline the path from early-stage formulation through commercial manufacturing. Rather than operating in isolated segments of the development lifecycle, some outsourcing partners are beginning to form more integrated collaborations designed to reduce handoffs, improve coordination, and simplify the client experience across multiple stages of manufacturing.

In this episode of Off Script, we spoke with David Leroux-Petersen, CEO of Corealis Pharma, and Jean-Baptiste (JB) Agnus, CCO of the CDMO division at Bora Pharmaceuticals, about the emerging role of CDMO-to-CDMO collaboration through the lens of a new partnership between their companies. The conversation explores how integrated outsourcing models can help reduce development risk and accelerate timelines, what operational alignment looks like across organizations with complementary capabilities, and why client-centricity, governance, and transparent communication are essential in complex manufacturing partnerships.

As pharmaceutical manufacturers push forward with massive capital expansion plans, challenges go beyond simply breaking ground on new facilities—it’s also managing the growing complexity, uncertainty, and resource strain that come with executing mega-projects. Persistent supply chain disruption, extended equipment lead times, rising material costs, and workforce constraints are forcing companies to rethink how they plan, govern, and prioritize capital investments in an increasingly volatile environment. 

In this episode of Off Script, we continued our conversation with Steve Cabano, president of Pathfinder, and Mark Christopher, vice president and head of the company’s pharmaceutical division, about the operational realities shaping large-scale pharmaceutical construction projects today. Pathfinder is a project management consulting firm. The discussion explores how post-pandemic supply chain instability and tariff uncertainty are impacting procurement strategies, scheduling assumptions, and project economics, with lead times for critical equipment stretching far beyond historical norms. We also examine the growing importance of portfolio-level governance as companies attempt to manage dozens of overlapping billion-dollar initiatives while maintaining existing operations, avoiding internal resource conflicts, and preparing for a future shaped by modularization, robotics, and AI-enabled project delivery.

Rising capital investment in pharmaceutical manufacturing is pushing projects to unprecedented scale, but execution strategies haven’t fully kept pace. As companies commit billions to new facilities they’re encountering a new set of challenges around planning, coordination, and risk management. What worked for smaller, site-based upgrades is insufficient for multibillion-dollar builds involving thousands of stakeholders, constrained resources, and increasingly complex regional dynamics.

In this episode of Off Script, we spoke with Pathfinder President Steve Cabano and Mark Christopher, vice president and head of the company's pharmaceutical division, about what it takes to successfully deliver mega-scale capital projects in today’s environment. Pathfinder is a project management consulting firm. The conversation explores how the industry’s shift back toward large-scale North American manufacturing is exposing gaps in project controls, contracting strategies, and organizational readiness. They discuss the growing importance of early-stage planning, clearer decision ownership, and construction-driven execution models, as well as how labor competition, permitting hurdles, utility constraints, and global procurement risks are reshaping timelines and cost structures.

Ever since the revised Annex 1 was published, drug makers have been navigating a broader transformation of sterile manufacturing that extends beyond compliance. Contamination control, in turn, is becoming a more proactive, data-driven, and highly collaborative model, one that emphasizes continuous improvement, global alignment, and deeper integration across the supply chain. While the regulation itself builds on decades of precedent, its latest iteration is accelerating expectations around risk management, documentation, and end-to-end control strategies.

In this episode of Off Script, we spoke with Haley Johnson, senior manager of product management, and Bill Matakas, vice president of business transformation at West Pharmaceutical Services, about how Annex 1 is reshaping sterile manufacturing operations and supplier relationships. The conversation explores the industry’s shift from reactive remediation to proactive risk prevention, the growing importance of contamination control strategies as living systems, and how inspectors are increasingly focused on measurable, year-over-year improvement. 

As the U.S. government pushes to reshore pharmaceutical manufacturing and rein in drug pricing, the implications for CDMOs and the broader outsourcing ecosystem are coming into sharper focus. While large-scale onshoring investments dominate headlines, questions remain around how policy will account for outsourced manufacturing and whether incentives align with the realities of global supply chains.

In this episode of Off Script, we spoke with Gil Roth, founder and president of the Pharma & Biopharma Outsourcing Association (PBOA), about how recent policy developments are impacting CDMOs and their customers. The conversation explores the role of CDMOs in onshoring efforts, the economic and structural barriers to reshoring API and generic drug manufacturing, and what current tariff frameworks signal about policy priorities. Roth also discusses FDA staffing challenges, potential impacts on drug review timelines, and the broader uncertainty shaping R&D, sourcing, and investment decisions across the industry.

While fully autonomous bioprocessing is within reach, adoption remains gradual as manufacturers navigate challenges around data maturity, regulatory expectations, and operational readiness. As companies modernize, the focus is shifting toward building the digital and organizational foundations needed to enable more intelligent, scalable process control, particularly through connected systems, stronger data infrastructure, and more explainable AI models that can support real-time decision-making.

In this episode of Off Script, we spoke with Mel Radford, director, life sciences global accounts at Rockwell Automation, about the key barriers to autonomy and how companies can move from reactive operations toward predictive and closed-loop process control. The conversation explores how hybrid models combining first-principles engineering with AI can improve control performance, stability, and yield while remaining transparent and easier to validate, as well as the importance of embedding compliance, governance, and human-centered change management into next-generation control strategies.

Generic medicines account for the vast majority of prescriptions in the U.S., yet much of their underlying supply chain remains heavily dependent on foreign-sourced active pharmaceutical ingredients (APIs). As concerns around drug shortages and supply chain resilience intensify, attention is shifting upstream toward how APIs are manufactured, where they are sourced, and what it will take to rebuild domestic production capacity. At the same time, advanced manufacturing approaches like continuous flow are gaining traction as a way to improve efficiency, safety, and cost competitiveness in a traditionally low-margin market.

In this episode of Off Script, we spoke with Brian Doty, vice president of R&D and programs at the API Innovation Center (APIIC), about the structural challenges facing generic drug manufacturing and the role advanced technologies could play in addressing them. The conversation explores why API supply is often the cause of downstream drug shortages, the technical and economic limitations of traditional batch processing, and how continuous manufacturing can reduce process steps, improve control, and enable safer production. Doty also discusses the practical barriers to adoption as well as the growing role of FDA engagement programs and policy incentives in accelerating change.

Antibody–drug conjugates (ADCs) are rapidly evolving from experimental hybrid molecules into mature, platform-driven therapeutics, with the global market projected to reach $36 billion by 2029. As pipelines expand and molecular designs grow more complex, developers are rethinking how ADCs are designed, characterized, and manufactured. In this episode of Off Script, we spoke with Lonza's Sandro Holzer, PhD, director and head of development bioconjugates, and Anette Sommer, PhD, head of bioconjugates research, about how the ADC field has changed over the last several years and what is driving the next wave of innovation.

The conversation explores the industry’s shift toward standardized linker–payload platforms, site-specific conjugation, higher drug-to-antibody ratios, and emerging dual-payload ADCs aimed at overcoming tumor heterogeneity and drug resistance. Holzer and Sommer discuss how rising molecular complexity is reshaping CMC strategy, analytics, and downstream processing, and why early integration of biology, chemistry, and manufacturability is essential to de-risk development and enable scale-up. The episode also examines how ADC manufacturing paradigms are now informing adjacent bioconjugate modalities signaling a broader move toward integrated, multi-component therapeutics beyond oncology.

Cell and gene therapies (CGTs) have demonstrated transformative clinical potential, but manufacturing remains a major barrier to broader patient access. Highly manual, labor-intensive production processes limit throughput, introduce variability, and drive up costs, making it difficult to scale these therapies to meet growing demand. As the industry looks to expand access, there is increasing focus on how automation, robotics, and digitalization can enable more consistent, efficient, and scalable manufacturing without compromising the underlying biology.

In this episode of Off Script, we spoke with Edwin Stone, PhD, CEO of Cellular Origins, about the core bottlenecks constraining CGT manufacturing and how automation is beginning to address them. The conversation explores why labor remains a dominant cost driver, how process variability extends beyond patient starting material into everyday manual operations, and what it takes to transition from fragmented workflows to fully integrated, robotic production environments. Stone also discusses the importance of preserving biological integrity during automation, the role of digital data capture in improving consistency and regulatory confidence, and more.