Sustainability impacts for converting to Raman spectroscopy inline monitoring from traditional offline manual sampling in small‐scale and large‐scale biomanufacturing

Abstract As biomanufacturing evolves to meet environmental goals, adopting innovative analytical technologies creates new pathways for sustainable process control. This study examines the impact of replacing traditional offline manual sampling with inline Raman spectroscopy for monitoring critical bioprocess parameters in both small‐ and large‐scale production. Conventional offline methods for measuring glucose, lactate, viable cell density and osmolality rely heavily on single‐use plastics and frequent manual handling, leading to increased waste and carbon emissions. Quantitative analysis shows that integrating inline Raman spectroscopy with predictive modeling can eliminate about 13.36 kg of single‐use plastic and prevent 80.17 kg of CO₂ emissions per combined run, with potential for greater annual impact. Raman‐enabled process analytical technology enables robust, real‐time monitoring, with model performance metrics ( R 2 and Q 2 ) consistently above 0.79 for key indicators, while also reducing contamination risk by maintaining closed systems. Although product quality and shipping emissions are not covered in this assessment, these results highlight considerable sustainability, operational and analytical advantages of Raman‐based monitoring. Implementing inline Raman spectroscopy advances AstraZeneca's and the industry's carbon neutrality and waste reduction goals, making it a transformative step for responsible bioprocessing. © 2025 AstraZeneca, PLC. Journal of Chemical Technology and Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry (SCI).