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Process economics evaluation of cell‐free synthesis for the commercial manufacture of antibody drug conjugates

Continuous improvements of cell‐free synthesis (CFS) systems have generated interest in adopting the technology for the manufacture of biologics. This paper provides an evaluation of the manufacturing cost‐effectiveness of CFS for the commercial production of antibody‐drug conjugates (ADCs). The evaluation was performed using an advanced techno‐economic engine (TEE) built in Python. The TEE is programmed in an object‐oriented environment capable of simulating a plethora of process flowsheets and predicting size and cost metrics for the process and the facility. A case study was formulated to compare the economics of whole bioprocesses based on either a CFS system or a mammalian cell system (CHO) for the manufacture of an ADC at a range of product demands. The analysis demonstrated the potential of CFS for the commercial manufacture of biologics and identified key cost drivers related to the system. The CFS system showed an approximately 80% increase in the cost of goods compared to CHO with a significant cost attributed to the in‐house manufacture of the bacterial cell extract, necessary for the CFS reaction step in the process. A sensitivity and target analysis highlighted the need for further process improvements especially in the titer for the CFS process to become more competitive against well‐established systems.