Peptide-based therapeutics, especially GLP-1 agonists, have become essential tools in treating chronic diseases like type 2 diabetes and obesity. But behind their clinical promise lies a manufacturing challenge since peptide production is complex, sensitive to scale, and often resource-intensive. 

At TAPI, we’ve turned this into an opportunity. 

By embedding Process Analytical Technology (PAT) into every step of the peptide manufacturing process, we’ve developed a smarter and greener platform—already implemented at GMP scale—that elevates process control, accelerates timelines, and reduces environmental footprint. 

This innovation is a model for how we support CDMO partners with demanding peptide programs. 

A Holistic, Data-Driven Approach 

Peptide manufacturing is inherently intricate, with limited in-process monitoring options and high sensitivity to deviations. Our cross-functional R&D and engineering teams tackled these challenges head-on by implementing a comprehensive PAT framework across synthesis, purification, concentration, and lyophilization. 

Application of such real-time PAT tools include: 

1. Refractive Index (RI) and ultraviolet spectroscopy (UV) monitoring in Solid Phase Peptide Synthesis (SPPS): Used during coupling and deprotection, RI detects deviations in reaction completeness or reagent flow, while UV confirms Fmoc removal via characteristic absorbance. Together, they provide real-time insight into reaction progress and enable early intervention, improving sequence integrity. 

2. Conductivity monitoring in wash steps: In-line conductivity sensors measure residues and by products species such as dibenzylfulvene (DBF) and piperidine during resin washing, allowing dynamic wash control based on predefined thresholds. This eliminates unnecessary solvent use and enables DMF recirculation without compromising quality. 

3. Near-Infrared (NIR) spectroscopy for piperidine residue monitoring: NIR enables in-line quantification of residual piperidine, ensuring effective washing before each coupling step. This improves process readiness while reducing DMF use. 

4. Conductivity and NIR in downstream purification: Conductivity monitoring controls buffer preparation via in-line dilution and defines wash endpoints during desalting and ion-exchange. NIR enhances robustness, and in some cases serves as a real-time control for acetonitrile gradient accuracy in HPLC. 

5. UV monitoring in continuous concentration on a Wiped Film Evaporator (WFE): UV-based PAT tracks peptide concentration during evaporation using WFE (wiped film evaporation). Initially applied as at-line IPC, this was upgraded to in-line UV, achieving concentrations up to 100 mg/mL for GLP-1 peptide. This enabled efficient lyophilization while maintaining product homogeneity. 

6. Pressure monitoring in lyophilization. Dual pressure sensors (Pirani and Barocel) define robust drying endpoints independent of scale or load. This prevents overdrying, which was previously linked to peptide aggregation, ensuring product stability and process consistency. 

The result? Shorter cycle times, enhanced robustness, and right-first-time production—crucial benefits in a field where variability has long been the norm. 

Proven at Scale, Ready for Partnership 

This isn’t a lab-scale concept. Our PAT-enabled platform is fully operational in GMP manufacturing and has already demonstrated a measurable impact: 

• Reduced solvent and energy use 

• Minimized human error through real-time monitoring 

• Enhanced product consistency across batches and scales 

• A digital foundation for future AI and machine-learning integration 

Whether you’re looking to de-risk development, scale a late-phase peptide, or secure long-term commercial supply—TAPI brings proven capabilities, advanced infrastructure, and CDMO flexibility to the table. 

The TAPI Advantage for Complex Peptides 

With decades of peptide experience, dual-site GMP capacity in Israel and Croatia, and modular technologies (SPPS, LPPS, hybrid), TAPI is uniquely equipped to support partners from early development to commercial launch. 

As a CDMO, we don’t just offer capacity, we offer chemistry innovation, analytical depth, and strategic thinking. Our teams understand the nuances of peptides and work with you to design scalable, sustainable processes that meet your molecule’s specific needs. 

Partner with TAPI for Your Peptide CDMO Needs 

From GLP-1 agonists to custom sequences, we’re redefining what’s possible in peptide manufacturing. If you’re seeking a partner who blends cutting-edge technology with reliable execution, let’s talk. 

Contact us to explore how TAPI can support your next peptide program. 

At TAPI, advancing health from the core also means protecting the environment at the core of everything we do. Across our Teva Tech site, we’ve launched a bold initiative to transform sustainability from a checklist into a culture, embedding greener practices into every aspect of manufacturing. 

From Program to Culture 

In the past, sustainability lived mainly in the domain of EHS&S. Today, it’s a cross-departmental mission, driven by a dedicated site-wide sustainability team. By bringing together expertise from engineering, operations, production, and beyond, we’ve sparked new levels of engagement, creativity, and ownership. Every employee has the opportunity to contribute—and every idea matters. 

The goal? To be sustainable in sustainability—making continuous improvement an everyday mindset. 

Innovation Meets Responsibility 

Our cross-functional approach has already led to tangible improvements: 

• Energy efficiency: Installing variable frequency drives (VFDs), optimizing compressors, and upgrading chillers. 

• Leak detection with next-gen tools: Using thermal, 360°, and sound cameras to spot and eliminate hidden leaks in nitrogen, air, and steam systems. 

• Green electricity: Since April 2024, Teva Tech has been powered exclusively by renewable energy, with IREC certification in progress. 

• Zero-liquid discharge mindset: Real-time monitoring of emissions, advanced wastewater treatment, and solvent recovery built into every new product. 

• Paperless production: Piloting electronic batch records to eliminate paper use and streamline compliance. 

• Smarter waste management: Campaigns for separation and recycling of plastics, metals, batteries, and more. 

These projects are designed not only to reduce energy, water, nitrogen, and steam consumption by 5–15% per year, but also to ensure measurable reductions in Scope 1 & 2 GHG emissions. 

A Win for Customers and Communities 

For our customers, sustainability is a shared priority. By reducing GHG emissions in all our sites in TAPI, we are helping our partners to achieve their ESG targets. At the same time, our initiatives strengthen supply reliability, reduce costs, and ensure compliance with local and global regulations. Beyond numbers, this program is shaping how our people think, act, and innovate. Every new project now runs through the lens of sustainability, making greener operations our standard way of working. 

Looking Ahead 

We see this as just the beginning. From exploring on-site energy storage to scaling AI-enabled monitoring systems, the journey to a greener future is ongoing. Most importantly, sustainability at TAPI is no longer just a department, it’s a shared responsibility and a source of pride. 

As a provider, partner, and pioneer, we are setting a new benchmark for green API manufacturing — one that benefits our industry, our customers, and the communities we live in. 

Fermentation is at the heart of many life-saving medicines. But when it comes to large-scale production, it’s one of the most unpredictable and complex processes in pharmaceutical manufacturing. At TAPI, we’ve taken a bold step toward solving this challenge—by combining data science, automation, and our deep process expertise to revolutionize how we manage substrate feeding in fermentation. 

The Challenge: Complexity in Every Drop 

As a global leader in active pharmaceutical ingredient (API) production, TAPI has a long-standing tradition of excellence in fermentation. Our largest fermentation site, based in Hungary, handles some of the most technically demanding production processes. These processes involve living organisms, over 200 hours of process time, and highly sensitive multi-variable conditions—all of which can lead to unpredictable yields and inefficiencies. 

One of the biggest variables? Substrate concentration. It needs to be maintained within an extremely narrow range throughout the entire process, which is no easy task with such complexity in play. 

The Solution: Smarter, Safer, and More Sustainable 

To meet this challenge head-on, we partnered with a specialist in process control to develop and implement an automated substrate feeding strategy. The result: a cutting-edge system powered by big data analytics, real-time prediction (via a “soft sensor”), and continuous concentration control. 

Key highlights include: 

• Real-time control: The system calculates and adjusts the substrate dosage rate automatically, removing the need for manual sampling and reactive adjustments. 

• AI-driven prediction: A soft sensor uses production data to predict substrate levels, enabling proactive decision-making. 

• Seamless integration: The algorithm was designed to fit into existing systems without disrupting ongoing operations. 

This wasn’t just a theoretical exercise—the system is live and delivering results. 

The Impact: Greater Efficiency, Lower Carbon Footprint 

Since implementing this control strategy, we’ve seen over a 15% increase in productivity, while simultaneously reducing our carbon footprint. By keeping substrate levels consistently optimal, the system minimizes fluctuations and improves reproducibility—two major pain points in any fermentation process. 

And the best part? This approach is scalable. The same control model can be tailored and applied to other fermentation processes across our sites, unlocking even broader improvements. 

Looking Ahead: A New Standard in Bioprocess Control 

What sets this development apart is not only the technology—but the mindset behind it. We’ve shown that internal know-how, combined with external collaboration and smart data use, can lead to real operational transformation. With this innovation, TAPI is setting a new benchmark for how fermentation can be controlled: more precise, more consistent, and more sustainable. 

This is just one example of how we’re advancing health from the core—by optimizing the very processes that make modern medicine possible.