Shaping the Future of Biomanufacturing: Inside Pionic® Platform
An expert roundtable with Jan Schaefer, Dr. Geert Lissens, and Paul Cashen, Sartorius
In a rapidly evolving biomanufacturing landscape, Sartorius convened three leading minds to share the strategic thinking and development journey behind Pionic® — a new, modular platform solution purpose-built for process intensification and continuous bioprocessing.
In this expert roundtable, Paul Cashen, Marketing Expert Bioprocess Solutions at Sartorius, leads a deep-dive discussion with Jan Schaefer and Dr. Geert Lissens. Together, they unpack how Pionic® platform was shaped through close collaboration with leading biomanufacturers and designed to meet the most pressing demands of modern production.
What follows is more than a product overview — it’s a behind-the-scenes look at how deep technical expertise, customer collaboration, and forward-thinking engineering came together to redefine what’s possible in intensified bioprocessing.
From Membranes to a Movement
Paul: What inspired the development of Pionic® platform and how does it reflect the company’s long-term vision for biomanufacturing innovation?
Geert: It all started with Sartobind® membranes, which established our early lead in downstream process intensification. Replacing traditional columns with membrane adsorbers was already a major shift, and customers embraced it. More recently, we expanded into protein A membrane adsorbers, making a significant impact in antibody processes. Sartorius has been pioneering intensification for nearly two decades.
Jan: Intensification is part of our DNA. Moving from resins to membranes, to investing early in single-use through our acquisition of Stedim, we’ve consistently enabled transformative shifts in manufacturing. Pionic® platform is the next chapter: expanding our toolbox so customers can adopt new, more efficient technologies.
Geert: Pionic® brings together the best of our innovations, starting with Sartobind® membranes, extending through Resolute® BioSMB and BioSC. It reflects a unified platform built from our strongest technologies. And as a leading single-use provider, we’re leveraging that strength to bring disposable, automation-ready solutions into the intensified and continuous space.
Collaboration at the Core
Paul: Customer collaboration was crucial in the development process of Pionic® platform. What were the most impactful outcomes of those collaborations, and how did they shape the final Pionic® platform?
Jan: Our goal was to bring together capabilities that had never been combined before. We collaborated with a leading biopharmaceutical company that brought deep expertise in integrated continuous bioprocessing, while Sartorius contributed our strength in equipment, consumables, and software. It was a perfect match.
To validate this disruptive innovation under real-world conditions, they provided unpurified mAbs, which we processed on early prototypes in our labs that ran continuously for more than 30 days. This close collaboration gave us immediate feedback on both system and process design, significantly accelerating development.
What made the partnership unique was their insight into regulatory and process orchestration, paired with our ability to scale hardware and consumables for commercial manufacturing. It was a true customer-centric development from concept to execution.
Paul: Would you say that the complementary nature accelerated the collaboration?
Geert: It definitely accelerated our project development because we could work with more speed and flexibility compared to our typical process.
Flexible Modularity = Strategic Advantage
Paul: Looking at the approach to continuous processing historically, it was mostly approached using batch systems, where you stick multiple systems together and if flow rates or volumes don’t match up, then you can patch that up with large surge bags or hold steps. Whereas Pionic® platform was designed with continuous process in mind and is suitable for lower flow rates and lower in-process volumes. In your opinion, is having a full platform with specific equipment to perform each unit operation — as opposed to a single system that is meant to do an entire process — the key advantage for the customer?
Jan: One of the most common pain points we hear is the lack of flexibility in intensified processing systems available. Pionic® platform addresses this directly. It’s modular, adaptable, and lets you begin your intensification journey at your own pace. You can scale up later, switch between molecules, adjust flow rates, and reconfigure unit operations using the same core system. It’s truly fit for purpose.
Unlike other technologies that allow some intensification but with trade-offs, Pionic® platform is built specifically for these scenarios. It’s optimized, not compromised.
Geert: Modularity exists at several levels. At the component level, it improves serviceability, training, and supply chain management, even if customers don’t see it directly. At the process level, you can swap modules in or out, or shift them across process steps based on volume needs. Unlike traditional batch systems, you don’t need to reinvest in new hardware each time your needs change.
Jan: We have a specific use case from a CDMO customer who intensified a compromised downstream train in their existing facility. They saw from our methodology that by implementing Pionic® platform, they could reduce their facility’s footprint by 50%, enabling them to run two parallel lines and double the number of molecules moving toward clinical trials.
In another case, a customer might have a limitation or bottleneck in their process. Here, we can simply de-bottleneck with this technology. By saving space with an intensified downstream train, you can free up space and scale out your upstream platform. This enables you to keep investments low at the beginning and implement a second bioreactor within a relatively short timeframe if needed. That’s a real benefit in terms of reducing your upfront investment risks. This is a powerful use case for existing fed-batch customers.
Fit-for-Purpose, Not Repurposed
Paul: How does Pionic® platform separate itself from existing intensification systems, both within Sartorius and also from other suppliers in the bioprocessing industry?
Geert: Few platforms offer the functionality of Pionic® platform. Early in development, we considered a one-size-fits-all system like others on the market, but we quickly saw the drawbacks: redundancy, inefficiency, and compromised performance.
Instead, we took a different approach. Pionic® platform is built with dedicated modules optimized for specific unit operations. This hybrid design balances flexibility with performance, and is one of its key innovations. We then enhanced it with advanced orchestration and automation to run unit operations in parallel, unlocking true system-based intensification, and not just consumable upgrades.
With Sartobind® membranes, we had already reduced footprint and improved efficiency. Pionic® platform takes this further by enabling a process-driven, automated intensification strategy.
Jan: To add to that, process intensification isn’t just about replacing components, it’s about controlling the process differently. The industry is already familiar with the underlying technologies. The real shift lies in how customers bring them together, and there are multiple approaches to achieving that integration.
Many suppliers simply connect off-the-shelf components. We designed Pionic® as a connected platform with orchestration in mind from the start, optimizing not just equipment, but how everything works together. For example, we cut out the intermediate bags and put smaller, optimized bags for recirculation or surging on top of the system. This optimizes the benefits in a way that combines modularity and fit-for-purpose equipment and minimized footprint.
Unlike others adapting fed-batch hardware for intensification, we built a system for intensified processing that can also support fed-batch when needed. It gives the end-users true flexibility in terms of mode of operation in their upstream processes. That’s a fundamental shift, and a key differentiator.
Scale for Today and Tomorrow
Paul: How do you approach the challenge of developing a platform of systems to meet the demands of processes that can vary quite a lot with regards to the volume of material needing to be processed?
Jan: In the past, we categorized platforms by development stage — process development, pilot, or commercial. But that doesn’t quite work for Pionic® platform because it’s based on volumetric flow. A specific flow for one modality represents pilot-scale material, while for other modalities, it is more commercial-size.
Right now, we’re focused on the S-sized platform, with a max flow of 150 L/h, and we’re planning XS and M variants to cover both smaller and larger scale needs. This evolution is important for customers across the range, and it’s a clear signal that Sartorius is committed to supporting the full drug lifecycle.
We launched the S platform first because our more advanced continuous processing customers saw the biggest challenge in upscaling their established Intensified Process Development tools in pilot scale, and argued that their processes still behave like batch and can be validated accordingly. In contrast, customers newer to intensification are requesting a smaller, XS-sized system to help them build confidence and scale up.
We’re also in discussions about higher-volume applications, including how to use Pionic® in multi-2,000 L bioreactor settings. That’s where the M platform will come in. Ultimately, we started at S because it was the sweet spot for early adoption, but we’re committed to growing the platform in both directions.
Accelerating New Modalities
Paul: How do you see Pionic® platform shaping the future of bioprocessing, especially for emerging modalities?
Geert: The initial focus of Pionic® platform is on monoclonal antibodies and protein-based therapies. We envision that the whole industry is moving toward connected and continuous for newer modalities, where we don’t have established workflows yet.
For newer modalities there's a major opportunity to improve yields and efficiency, especially at the unit operation level. In particular, the XS platform could accelerate the shift to connected and continuous processing for these therapies, reducing the decades-long timeline we saw with mAbs.
Jan: Even for traditional modalities, Pionic® platform opens new possibilities. Its flexibility and modularity make it easier for customers to transition from fed-batch to intensified processing. For some customers, the intention is always to use the same cell line and decide the best way to manufacture the drug later, depending on the quantity they need to produce. Pionic® supports that journey, starting with fed-batch, then moving into intensification when needed. That level of adaptability is something only we offer.
Automation That Works for You
Paul: Earlier you mentioned the role of automation in intensification. What role do automation and digital solutions play in relation to Pionic® platform?
Geert: Automation and digital solutions are some of the most important factors influencing why customers choose to adopt a platform because it enables them to increase data generation. Over the last two decades, the trend has been to gather more and more data from a process, and to do something meaningful with it. Lots of data is still recorded manually, and this platform enables users to make the best use of the data to start predicting how the process is going to behave by monitoring critical quality attributes.
A major barrier to integrated continuous biomanufacturing is the lack of advanced process analytical technology (PAT). Pionic® platform supports the development of new PAT tools, helping to close that gap with smarter automation and control.
Jan: Traditionally, automation suppliers leave orchestration to the customer. Translating a process into an intensified, automated system requires major effort — and risk — on the user’s part. With Pionic® platform, we’ve flipped that model. Our platform includes built-in orchestration, with fully integrated units that communicate seamlessly. It’s a true turnkey solution for intensification, which sets us apart.
Geert: It’s a stepwise approach. From our discussions with customers, one of the biggest concerns is understanding what to do in case there’s a deviation. So, we need to have some safety stops built in — we’re still using small surge tanks in between unit operations and through our collaborations, we’re working to get the system fully continuous. This gives us insights on how we can solve deviations, or compensate for them using automation.
Adapting with Intention: Partial Versus Full Implementation
Paul: Pionic® platform exists both as a full end-to-end system and as individual modules. How do you view partial implementation versus deploying the full platform?
Geert: We started launching the first modules for early access around chromatography operations because the capture step is the most expensive and has the greatest potential for intensification. Most customers begin there, then gradually add viral inactivation and polishing steps, using a step-by-step intensification approach. As Jan mentioned before, the other approach is to de-bottleneck unit operations with Pionic® platform by using multiple systems, depending on the intensification strategy that the customer wants to implement.
Jan: The value lies in flexibility. You might run an intensified process one day and batch the next, using the same unit. That saves on investment, space, qualification, and maintenance. You can decide based on your daily operational needs without committing to one mode or building new infrastructure.
Paul: So, companies running multi-product facilities, like CDMOs or big pharma, stand to benefit the most?
Jan: CDMOs definitely grasped the value early on. Now, based on our discussions with customers, we see a clear shift in mindset. More companies recognize that future production will demand flexibility — batch, perfusion, or hybrid — and they need a system that allows them to adapt without building new rooms or sites.
Geert: Consider that customers need to build facilities before identifying which specific modalities they will be for — that highlights the need for a flexible platform that can run multiple modalities. With unpredictable market demands, they need a platform that can flex across products and processes — Pionic® platform gives them that versatility from day one.
A Platform for What’s Next
As biotech and pharma companies face increasing pressure to move faster, scale smarter, and adapt to changing demand, Pionic® platform offers a way forward. Rooted in decades of intensification experience and developed in close collaboration with industry leaders, it’s more than just a system — it’s a strategy.
Whether you're intensifying one step or building a fully continuous facility, Pionic® platform is built to grow with you.
Learn more about Pionic® today.
Jan Schäfer manages the Separation Systems product portfolio at Sartorius Stedim Biotech. In this role, he leads global product management and product development teams. He provides customers with process solutions for downstream applications and for the transition from classic batch operation to intensified, continuous bioprocessing.
He has previously held roles in project and product management, process consultancy, as well as several leadership positions. With more than 15 years of experience in bioprocess engineering and design, his most significant accomplishments include several innovative product launches in single-use downstream processing, and designing and implementing a global single-use downstream platform process for purifying biologics at facilities in Europe, the US, and Asia. He is named inventor on several single-use and downstream patents, and invented the first fully single-use crossflow system. Jan holds an engineering diploma in bioprocess engineering from Technical University of Braunschweig in Germany.
Geert Lissens is a seasoned biotech and healthcare professional with more than 20 years of experience in bioprocessing, spanning technical, sales, marketing, and product leadership roles. As Head of Product Management at Sartorius since 2016, he drives innovation and strategic development for downstream systems and instruments, including analytical, filtration, and chromatography solutions.
His career trajectory reflects a strong blend of commercial insight and technical depth, having served in regional and global leadership roles in product management, innovation, and segment marketing. Prior to Sartorius, he held senior sales and business development positions at JSR Micro, Merck Millipore, and Millipore, where he focused on biopharma purification, process solutions, and account growth.
Geert holds dual PhDs in Bio-engineering and chemical engineering from KU Leuven and Ghent University, as well as a master’s degree in bioengineering. He is multilingual and has deep industry relationships across the biopharma industry, consistently promoting process intensification, sustainability, and strategic partnerships.
Paul Cashen is a Marketing Expert for Bioprocessing Solutions at Sartorius. He has more than 15 years of experience in the biologics industry, with expertise in downstream processing and analytical development. He specializes in the downstream process development, scale-up and manufacturing of ATMPs, such as lentiviral and adeno-associated viral vectors, as well as process intensification strategies for downstream purification. In his current role, he is responsible for developing and executing modality-based marketing strategies and driving thought-leadership initiatives.
