5 Key Takeaways

• 1

  The review characterizes continuous biomanufacturing as a process-control and system-integration challenge requiring coordination among sensors, models, and control systems.

• 2

  PID control suits stable, well-measured variables, whereas model predictive control can manage interacting variables, delayed measurements, and operating constraints.

• 3

  Process analytical technology supports control, but sensor cost and calibration drift can limit in-line and online measurements; at-line sampling may suit slower processes.

• 4

  Soft sensors can estimate unmeasured attributes but remain vulnerable to sensor noise and model error, which could prompt inappropriate control actions.

• 5

  The authors propose introducing digital twins gradually, with advanced control justified by measurable gains in product recovery, consistency, or risk management.