Siegfried

Thomas Carl

In an interview with Life Sciences Review magazine, Carl provides valuable insights into the industry's evolving needs and the significance of emerging technologies in shaping its future.

Can you provide an overview of your professional journey, educational background and key roles and responsibilities at Siegfried?

I studied chemistry at the University of Stuttgart in Germany and the University of Reading in the UK. I pursued a PhD at the University of Basel, focusing on electron transfer in DNA and related methods. Following this, I pursued postdoctoral research at the University of California, Berkeley, working on the total synthesis of a complex molecule.

My career began in Switzerland with Ciba Specialty Chemicals, where I worked as a chemist for a new development project and later managed a group responsible for niche products. I also took on the roles of Deputy Plant Manager and Plant Manager during the merger with BASF. After my tenure at Ciba Speciality Chemicals, I joined Novartis as a senior process manager. Later, I shifted to SI Group, leading production and serving as the site director in Switzerland. Currently, with Siegfried, I've been heading the Chemical Development Process R&D and Scale-up for over four years, managing global responsibilities across Switzerland, Germany, and China.

With your extensive experience working at Siegfried, what challenges have you faced or are currently facing?

We face a significant challenge in process development due to the need to shorten project timelines. This has put immense pressure on us to deliver high-quality work within tighter schedules. At Siegfried, we've chosen an adaptive approach called the "toolbox approach," which combines digital simulations and real-world experiments to create custom-tailored developments.

Sustainability is another critical challenge, with increasing customer demands for greener processes. Nonetheless, we're actively redesigning processes to foster sustainability and facilitate cost-competitive second[1]generation processes.

How does your organization navigate the regulatory landscape to ensure compliance and safety during the process development?

Process safety is inherently integrated into process development at Siegfried. We conduct process safety investigations throughout the development process, employing techniques like differential scanning calorimetry and using reactor calorimeters to assess the behaviour and criticality of our processes. This early assessment helps identify potential safety issues and make necessary adjustments.Furthermore, we employ simulation tools to enhance safety. We also apply process analytical technologies(PAT) to design, analyze, and control our pharmaceutical manufacturing processes.

Are there any emerging technologies that you believe will play a significant role in shaping the future of process development?

While not entirely new, emerging technologies like flow chemistry and continuous processing, especially in downstream activities, are poised to reshape the future of process development. Batch distillation or batch extractions are lacking in the pharmaceutical industry, and there is potential for significant improvement. We’re also exploring ultrafiltration and nanofiltration techniques.

“We face a significant challenge in process development due to the need to shorten project timelines. This has put immense pressure on us to deliver high-quality work within tighter schedules”

Additionally, we're focused on integrating Process Analytical Technologies (PAT) on a larger scale to gain real-time insights and make data-driven decisions, improving process control. Simulation tools for crystallization and other processes are also becoming more sophisticated and valuable in process development.

Do you have any advice for other senior leaders and CMOs in the industry?

My advice for senior leaders in the industry and CMOs is to have confidence in your capabilities and expertise. In the face of tight schedules, it's essential to recognize your strengths and know what you can handle. Build expertise within your organization and embrace new ideas and technologies, even if they require effort to implement, as these innovations can lead to significant improvements in quality, efficiency, and sustainability. Being self-confident and proactive in offering innovative solutions can set you apart and provide substantial benefits to the industry and customers.