Continuous Manufacturing Market Set to Double by 2035, Driven by Innovation and Growing Demand

The pharmaceutical manufacturing world is on the cusp of a major transformation. For decades, drug production relied on batch processing-a method akin to baking a cake in stages, where each step must finish before the next begins. But imagine if you could bake that cake continuously, without stopping, producing fresh slices all day long. That's the promise of continuous manufacturing, and it's reshaping how medicines are made.

Roots Analysis recently unveiled a comprehensive report revealing that the global continuous manufacturing market is projected to soar from USD 2.08 billion in 2023 to an impressive USD 4.36 billion by 2035, growing at a steady compound annual growth rate (CAGR) of 6.4%. This shift is not just a trend but a fundamental change in pharmaceutical production, promising faster, more efficient, and higher-quality drug manufacturing.

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Why Continuous Manufacturing?

Traditional batch manufacturing involves multiple sequential steps with hold times in between, often leading to inefficiencies and delays. Continuous manufacturing, on the other hand, integrates all production steps into a seamless, 24/7 operation within a single facility. This approach reduces production time, minimizes waste, and enhances product consistency-critical factors in delivering life-saving drugs to patients faster.

Market Segmentation Highlights
1. Drug Molecule Types: Small molecules currently dominate the market, accounting for over 50% of revenue in 2023. However, biologics-the complex, large-molecule drugs-are expected to grow faster, with an annual growth rate nearing 9%.

2. Manufacturing Purpose: For biologics, contract manufacturing leads with more than 65% market share, while in-house manufacturing is rapidly growing at over 13% annually. Conversely, small molecules see in-house manufacturing leading with 55% share, but combined in-house and contract manufacturing is the fastest-growing segment.

3. Product Types: Active pharmaceutical ingredients (APIs) dominate biologics manufacturing (over 90% share), but finished dosage forms are the fastest-growing segment. For small molecules, finished dosage forms hold over 90% share and are expected to grow as more continuous manufacturing approvals come through.

4. Scale of Operation: Commercial production leads both biologics (80% share) and small molecules (95% share), yet preclinical and clinical manufacturing segments show strong growth potential.

5. Bioprocessing Stages: Upstream bioprocessing (early-stage production) commands over 90% of the biologics market, but downstream processing (purification and finishing) is growing fastest.

6. Company Size: Very large companies dominate biologics continuous manufacturing, while mid-sized firms lead in small molecules. Large companies in both sectors are poised for significant growth.

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Regional Outlook

Europe currently holds the largest share of the continuous manufacturing market and is expected to maintain this lead through 2035. Meanwhile, the Asia Pacific region is the fastest-growing market, reflecting increasing pharmaceutical investments and manufacturing capabilities.

Industry Dynamics and Innovation

The market landscape is vibrant and competitive, with around 60 players globally engaged in continuous biologics manufacturing, mostly offering contract services. The biologics sector is fragmented, featuring both established giants and innovative newcomers, primarily based in the U.S. For small molecules, about 50 manufacturers claim expertise in continuous processes, mostly large firms.

Partnerships and collaborations are booming, with 2023 seeing the highest number of deals related to continuous manufacturing. Companies are actively upgrading capabilities and expanding capacity to meet clinical and commercial demands.

Since 2020, nearly 700 patents have been filed or granted in this domain, underscoring rapid innovation. Research grants exceeding USD 45 million have supported continuous manufacturing studies, many extending over five years.

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Looking Ahead

The biologics continuous manufacturing market is expected to grow at a robust CAGR of 8.8%, driven by upstream and downstream bioprocessing advances. Small molecule continuous manufacturing will grow more modestly at 3.4%, with North America capturing over half the market by 2035.

Key Players to Watch

Industry leaders shaping this evolution include Abbvie Contract Manufacturing, ACG Group, Boehringer Ingelheim, Corden Pharma, Glatt Group, Kaneka, Phlow, and WuXi Biologics.

A Real-World Perspective

Consider a pharmaceutical company that traditionally produced a blockbuster drug in batches, facing delays and quality variability. By transitioning to continuous manufacturing, they now run a streamlined, nonstop process that cuts production time by half and improves product consistency. This not only accelerates patient access but also reduces costs-a win-win scenario illustrating why the industry is embracing this shift.

In Summary

Continuous manufacturing is more than a technological upgrade; it's a paradigm shift in pharmaceutical production. With strong market growth, technological innovation, and expanding global adoption, this approach promises t
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Roots Analysis
Gaurav Chaudhary
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Roots Analysis is a global leader in market research, competitive intelligence and consulting services across industries. Having worked with over 750 clients worldwide, including Fortune 500 companies, start-ups, academia, and venture and strategic investors for more than a decade, we offer a highly analytical / data-driven perspective to a network of over 450,000 senior industry stakeholders looking for credible market insights. All reports provided by us are structured in a way that enables the reader to develop a thorough perspective on the given subject. Apart from writing reports on identified areas, we provide bespoke research / consulting services dedicated to serving our clients in the best possible way.

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