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Beyond Biotech

Freeze variability, not progress: strengthen your cell therapy supply chain from the start

30 min episode · 2 min read
·
Dominic Clark

Episode

30 min

Read time

2 min

Topics

Productivity, Health & Wellness, Leadership

AI-Generated Summary

Key Takeaways

  • Fresh vs. Frozen Starting Material: Fresh workflows persist due to inherited academic processes, not data superiority. Once programs enter the clinic with fresh workflows, those decisions become locked in — making later pivots costly and regulatory-intensive. Teams should evaluate cryopreservation at Phase I design, not during scale-up, to avoid forced process changes under high regulatory scrutiny.
  • Automated Closed Process (ACP) Design: IntegraCell's ACP uses a Fresenius Kabi Q system to automate leukapheresis washing, concentration, cryoprotectant formulation, and bag filling in a closed system. This removes operator-dependent manual handling steps, reducing two primary variability sources — time and people — while producing cell viability and recovery comparable to fresh starting material.
  • Cryopreservation as Regulatory Strategy: Validated cryopreservation strengthens regulatory submissions by demonstrating reproducibility and process control. Data from an IntegraCell-CellAd collaboration showed the ACP preserves key T cell subsets, activation profiles, and phenotypic identity at levels functionally equivalent to fresh material, providing documented evidence regulators can assess for consistency across manufacturing batches.
  • Multi-Site Standardization Gap: A single validated cryopreservation process deployed across multiple collection sites eliminates site-to-site variation. IntegraCell addresses this by offering the same ACP protocol, quality system, and SOPs across all global locations — including a Paris facility opened in 2024 and a Southern California site opening in 2025 — rather than allowing each site to run independent manual variants.
  • Proactive Dual-Track Planning: Programs committed to fresh workflows should still develop and validate a cryopreserved starting material option in parallel. Maintaining a frozen backup decouples manufacturing from clinical scheduling, enables inventory management, and provides operational flexibility if logistics, patient geography, or scale demands shift — without requiring a disruptive mid-program process change under regulatory review.

What It Covers

Dominic Clark, VP of Technical Operations at IntegraCell (Cryoport Systems), explains why cell therapy programs default to fresh leukapheresis workflows, how late-stage cryopreservation adoption creates costly regulatory and operational problems, and how IntegraCell's automated closed process standardizes starting material handling from early development through global commercialization.

Key Questions Answered

  • Fresh vs. Frozen Starting Material: Fresh workflows persist due to inherited academic processes, not data superiority. Once programs enter the clinic with fresh workflows, those decisions become locked in — making later pivots costly and regulatory-intensive. Teams should evaluate cryopreservation at Phase I design, not during scale-up, to avoid forced process changes under high regulatory scrutiny.
  • Automated Closed Process (ACP) Design: IntegraCell's ACP uses a Fresenius Kabi Q system to automate leukapheresis washing, concentration, cryoprotectant formulation, and bag filling in a closed system. This removes operator-dependent manual handling steps, reducing two primary variability sources — time and people — while producing cell viability and recovery comparable to fresh starting material.
  • Cryopreservation as Regulatory Strategy: Validated cryopreservation strengthens regulatory submissions by demonstrating reproducibility and process control. Data from an IntegraCell-CellAd collaboration showed the ACP preserves key T cell subsets, activation profiles, and phenotypic identity at levels functionally equivalent to fresh material, providing documented evidence regulators can assess for consistency across manufacturing batches.
  • Multi-Site Standardization Gap: A single validated cryopreservation process deployed across multiple collection sites eliminates site-to-site variation. IntegraCell addresses this by offering the same ACP protocol, quality system, and SOPs across all global locations — including a Paris facility opened in 2024 and a Southern California site opening in 2025 — rather than allowing each site to run independent manual variants.
  • Proactive Dual-Track Planning: Programs committed to fresh workflows should still develop and validate a cryopreserved starting material option in parallel. Maintaining a frozen backup decouples manufacturing from clinical scheduling, enables inventory management, and provides operational flexibility if logistics, patient geography, or scale demands shift — without requiring a disruptive mid-program process change under regulatory review.

Notable Moment

Clark reframes the core tradeoff by arguing that fresh workflows optimize for immediacy while frozen workflows optimize for scale — and that the real source of quality risk in cell therapy is not freezing itself, but uncontrolled variability introduced through manual handling and fragmented multi-vendor handoffs.

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Episode Transcript

Hello, and welcome to Beyond Biotech, the weekly podcast from LaViaTech. My name is Dylan Kossain, and this is episode 197 for the podcast. Today, we're digging into a topic that's getting a lot more attention lately. How early decisions in cell therapy end up shaping or complicating everything that comes later. Our episode today is freeze variability, not progress, how to strengthen your cell therapy supply chain from the start, and we're going to challenge a few long held beliefs about how starting material should be handled. My guest today is Dominic Clark, vice president of technical operations for IntegraCell at Cryoport Systems. Dominic has spent years in the trenches building and scaling cell therapy processes from early development through commercialization. So we've seen where things break and what actually works. I hope you enjoy my conversation with Dominic Clark. Dominic, it's great to have you here today. We know Cryoport Systems well here at Beyond Biotech, but for anyone tuning in who might be new, can you give us a quick refresher on what Cryoport Systems focuses on and maybe tell us a little bit about IntegraCell and how it fits into the bigger picture? Yeah. Absolutely. And, yeah, first of all, thank you for having me here today as we, you know, dive deeper into the industry norms and and challenging some of those norms for the cell therapy supply chain. You know, as, as you said, you know, Cryopore Systems is a global leader in temperature controlled supply chain solutions for the advanced therapies. We support the full vein to vein journey, to protect irreplaceable materials, but, you know, it's because of that end to end visibility that we see firsthand where variability and risk actually commonly enter the system. And it's this unique position that allows us to translate those direct insights into our solutions and best partner with our customers to enable patient access at a global scale. IntegraCell is the part of the is a is a part of that complete platform that focuses specifically on the incoming patient starting material. IntegraCell essentially enables consistent cryopreservation of leukapheresis starting material through a standardized automated platform or process that we've developed and put in place. And our goal within IntegraCell and across all of cryoport systems is to simply, you know, build a reliable foundation that supports the development, the scale up, and certainly the most important, you know, aspect is long term success for our customers. And before we get into the technical side of things, I'd love to give listeners a sense of what you personally focus on. Where do you spend most of your time at IntegraCell? You know, I may maybe I'll just kinda step back for a second and and maybe it'll help to understand. And so my and I've been a I've been living and breathing, selling gene therapies, my entire working career. And, you know, I would say that, you know, I don't know if this is …

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Books, tools, and gear mentioned in this episode

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Gear

  • by Fresenius Kabi

    IntegraCell's ACP uses a Fresenius Kabi Q system to automate leukapheresis washing, concentration, cryoprotectant formulation, and bag filling in a closed system.

company

  • Dominic Clark, VP of Technical Operations at IntegraCell (Cryoport Systems)...
  • Data from an IntegraCell-CellAd collaboration showed the ACP preserves key T cell subsets, activation profiles, and phenotypic identity...
  • Dominic Clark, VP of Technical Operations at IntegraCell (Cryoport Systems), explains why cell therapy programs default to fresh leukapheresis workflows...

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