Digital Twins in Biopharmaceutical Manufacturing: Review and Perspective on Human–Machine Collaborative Intelligence

Mohammed Aatif Shahab; Francesco Destro; Richard D. Braatz

doi:10.1016/j.eng.2026.07.039

Engineering ›› :202607039 DOI: 10.1016/j.eng.2026.07.039

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Digital Twins in Biopharmaceutical Manufacturing: Review and Perspective on Human–Machine Collaborative Intelligence

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Abstract

The biopharmaceutical industry is increasingly developing digital twins to digitalize and automate the manufacturing process in response to the growing market demands. However, this shift can create challenges for human operators, as the complexity and volume of information can overwhelm their ability to manage the process effectively—particularly during abnormal events. These issues are compounded when digital twins are designed without explicit consideration of operator interaction and collaboration. Our review of current trends in biopharma digital twin development reveals a predominant focus on technology and often overlooks the critical role of human operators. To bridge this gap, this article proposes a collaborative intelligence framework that integrates operators with digital twins. We discuss approaches that can enhance operator trust and human–machine interface usability. Moreover, innovative training programs for preparing operators to understand and utilize digital twins are discussed. The framework aims to strengthen collaboration between operators and digital twins by leveraging their complementary capabilities to improve resilience and productivity in biopharmaceutical manufacturing.

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Biopharmaceutical industry / Digital twin / Digitalization / Human–machine collaboration

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Mohammed Aatif Shahab, Francesco Destro, Richard D. Braatz. Digital Twins in Biopharmaceutical Manufacturing: Review and Perspective on Human–Machine Collaborative Intelligence. Engineering 202607039 DOI:10.1016/j.eng.2026.07.039

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