Biopharmaceutical manufacturing requires scalable, cost-effective training that prepares workers for complex upstream and downstream operations. Traditional equipment-based training is expensive, limited in capacity, and cannot replicate rare failures critical for troubleshooting skills. As digital transformation accelerates, the industry needs flexible, immersive solutions that provide realistic practice without safety or compliance risks.
A digital twin–enabled platform meets this need by offering 24/7 access to virtual bioprocess environments, structured learning prompts, and interactive SOPs. This approach builds technical competency and problem-solving skills while reducing training costs and improving workforce readiness for modern biomanufacturing operations.
The implementation of a Digital Twin allows successful scale-up, implementation and operation to satisfy stringent clinical and regulatory requirements, while ensuring appropriate business and cost structures.
Blended training resources created using video, animation, and virtual reality. These modules will engage students in online courses while providing a simulated hands-on experience.
A HakoBio platform builds a Digital Twin for one upstream operation (rocker bioreactor) and one downstream operation (tangential flow filtration/TFF) as proof-of-concept.
The virtual nature of the training platform inherently allows updating, scaling and distribution as core benefits. The platform is also not only a training platform; it can be used for assessment as part of an educational tool, establishing credentials or to obtain continuous learning credits.
Further value of a VR/MR Digital Twin solution lies in the fact that it is a scalable platform which provides an immersive experience for rapid assimilation of new concepts.
Developed a comprehensive bioprocessing curriculum aligned with workforce needs and industry standards, covering upstream and downstream processes from cell culture through purification.
Created an accessible online learning platform featuring immersive digital twin technology and virtual reality for autonomous, self-directed learning.
Digital twin environment enables realistic application of knowledge, hands-on practice, and troubleshooting through intentional error introduction; accessible 24/7 and always up to date.
Integrated structured learning prompts and interactive SOPs to guide learners and reinforce skill-based competencies through assessments mapped to defined objectives.
Conducted an IRB-approved study with 36 students to evaluate and refine the curriculum and platform, ensuring evidence-based improvements and future connection to physical equipment training.
Behrens, S., Exploring Bioprocessing Education via Digital Twin Technology, NIIMBL Member Forum, Virtual, October 27, 2022.
Login to the NIIMBL member portal to access additional project information, including presentations, progress updates, reports, and more.
Not yet a member? Learn more about which level of NIIMBL membership is right for you and your organization.
Keck Graduate Institute
California Polytechnic State University
Catalent Pharma Solutions, LLC
Merck Sharp & Dohme LLC
OUAT!
Santa Clara University
Sartorius Stedim
