Breaking the Bottleneck: How Modular Workflows Are Redefining CAR T Manufacturing Performance, Flexibility, and Scalability

As cell therapies advance toward commercial-scale manufacturing, developers can face increasing pressure to balance performance, scalability, and process flexibility. Flexible modular workflows are emerging as a powerful approach for scalable cell therapy manufacturing, enabling enhanced process control, workflow adaptability, and operational efficiency while maintaining consistency across the manufacturing pipeline. These advantages can be particularly valuable in environments where evolving process requirements may challenge more fixed manufacturing approaches.

In this webinar, we will explore how modular Gibco™ CTS™ workflows compare to an integrated system across critical CAR T manufacturing quality attributes, including transduction efficiency, T cell activation, expansion, and phenotype preservation. Data demonstrate that modular workflows can achieve high transduction efficiency (up to ~80% by day 8), increased CAR+ T cell yields, and enhanced enrichment of stem cell–like memory (TSCM) populations, which can be key factors associated with improved therapeutic potential.

We will also highlight how flexibility in workflow design enables parallel processing, reduced instrument lock times, and improved operational efficiency, without compromising cell quality metrics such as purity and isolation efficiency. Attendees will gain practical insights into how modular strategies can future-proof manufacturing processes and support both early development and commercial-scale production.

Key Learning Objectives

Understand how modular workflows impact critical CAR T manufacturing attributes, including transduction efficiency, expansion, and T cell phenotype
Evaluate the trade-offs between integrated and modular systems in terms of scalability, flexibility, and operational efficiency
Learn how flexible workflow design can enable parallel processing, reduce bottlenecks, and support evolving process requirements