Single-use Bioreactors: Driving the Future of Biomanufacturing

The biopharmaceutical industry is rapidly evolving, with efficiency, scalability, and flexibility at the forefront of production strategies. One technology that has transformed modern biologics manufacturing is Single-use Bioreactors (SUBs). These disposable systems are replacing traditional stainless-steel setups due to their cost-effectiveness, faster turnaround, and reduced risk of contamination.

In this blog, we’ll explore what single-use bioreactors are, their benefits, applications, and future market potential.

Market Forecast Snapshot

The global single-use bioreactors market, valued at US$4.1 billion in 2023, stood at US$4.4 billion in 2024 and is projected to advance at a resilient CAGR of 15.4% from 2024 to 2029, culminating in a forecasted valuation of US$9.1 billion by the end of the period. This growth reflects the increasing adoption of flexible manufacturing systems, rising biologics demand, and regulatory acceptance of disposable technologies.

What are Single-use Bioreactors?

Single-use bioreactors are disposable, pre-sterilized vessels used for cultivating cells and producing biologics such as vaccines, monoclonal antibodies, and cell therapies. Unlike traditional stainless-steel bioreactors, SUBs use plastic liners and components that are discarded after each batch, eliminating the need for complex cleaning and sterilization.

Benefits of Single-use Bioreactors

1. Cost Efficiency

• Lower capital investment compared to stainless-steel systems
• No need for expensive cleaning validation processes
• Reduced utility costs (water, steam, cleaning agents)

2. Faster Turnaround

• Quick setup and batch changeover
• Ideal for multi-product facilities and contract manufacturing organizations (CMOs)

3. Flexibility & Scalability

• Suitable for small-scale clinical trials and large-scale commercial production
• Easily adaptable to different cell culture processes

4. Reduced Contamination Risk

• Pre-sterilized, disposable bags minimize cross-contamination risks
• Enhances product quality and safety

Applications of Single-use Bioreactors

Biopharmaceutical Production

Widely used in manufacturing monoclonal antibodies, vaccines, and recombinant proteins.

Cell and Gene Therapy

Support small-batch, highly customized therapies that require rapid scale-up.

Research and Development (R&D)

Allow flexibility in early-phase drug development, reducing time-to-market.

Market Drivers

• Rising Demand for Biologics: Increased prevalence of chronic diseases fuels demand for monoclonal antibodies and vaccines.
• Growth of Contract Manufacturing: CMOs are adopting SUBs for cost-effective and flexible production.
• Regulatory Acceptance: Growing trust from regulatory agencies in the quality and safety of single-use technologies.
• Advancements in Design: Modern SUBs now support large-scale commercial production with improved sensors and automation.

Challenges to Overcome

• Plastic Waste Concerns: High volume of disposable bags contributes to environmental burden.
• Scalability Limits: Large-scale bioreactors (over 2,000 liters) still face engineering challenges.
• Supply Chain Dependence: Heavy reliance on specialized suppliers for single-use components.

Future Outlook

With continuous innovation, single-use bioreactors are expected to dominate biomanufacturing over the next decade. Integration with digital bioprocessing, automation, and real-time analytics will enhance efficiency, sustainability, and scalability.

As the market nearly doubles by 2029, SUBs will become the cornerstone of both established pharmaceutical companies and emerging biotech startups.

Practical Tips for Biopharma Companies

• Evaluate Process Scale: Choose SUB sizes aligned with production goals (R&D vs. commercial scale).
• Plan for Waste Management: Incorporate recycling initiatives where possible.
• Leverage CMOs: For smaller firms, outsourcing to CMOs with established SUB facilities can reduce costs.
• Stay Updated with Regulations: Ensure compliance with evolving GMP and environmental guidelines.

Conclusion

Single-use bioreactors are no longer just an alternative—they are becoming the industry standard in biologics manufacturing. With significant cost savings, operational flexibility, and reduced contamination risks, they enable faster, safer, and more sustainable production.

As the global market surges toward US$9.1 billion by 2029, adopting SUBs can help biopharma companies stay competitive, accelerate drug development, and meet patient needs more effectively.

If your organization is exploring innovative biomanufacturing solutions, now is the time to invest in single-use bioreactor technologies. Stay ahead of the curve—embrace flexibility, sustainability, and scalability.