SUS (Single Use System) for Biopharma Process Market, Global Outlook and Forecast 2025-2032

MARKET INSIGHTS

Global SUS (Single Use System) for Biopharma Process market was valued at USD 4.98 billion in 2023 and is projected to reach USD 18.92 billion by 2030, exhibiting a remarkable CAGR of 21.0% during the forecast period. This accelerated growth reflects biopharma's increasing shift toward flexible manufacturing solutions.

SUS (Single Use Systems) refer to pre-sterilized, disposable bioprocessing equipment designed for one-time use in pharmaceutical manufacturing. These systems eliminate cleaning validation requirements and reduce cross-contamination risks while improving operational efficiency. The market primarily includes single-use bioreactors, disposable sterile bags, and filtration systems that enable faster production turnaround times.

The market expansion is driven by biopharmaceutical companies' need for cost-effective, scalable solutions - particularly for biologics and vaccine production. However, material supply chain considerations and environmental concerns about plastic waste present ongoing challenges. Major players like Danaher, Thermo Fisher, and Sartorius collectively dominate 73% of the market, with North America and Europe each holding 32% market share, followed closely by Asia-Pacific at 31%.

MARKET DYNAMICS

MARKET DRIVERS

Growing Biopharmaceutical Pipeline to Accelerate SUS Adoption

The global biopharmaceutical pipeline has witnessed exponential growth, with over 10,000 drug candidates currently in development across various stages. This surge is directly fueling demand for flexible and cost-effective manufacturing solutions like single-use systems. Traditional stainless-steel bioreactors require high capital investment and lengthy validation processes, whereas SUS offers plug-and-play functionality that reduces facility footprint by up to 40%. The ability to rapidly deploy SUS technology significantly shortens time-to-market for novel biologics - a critical advantage when commercializing therapies for emerging diseases.

Precision Medicine Advancements Driving Modular Production Needs

With the personalized medicine market projected to exceed $5 billion annually, biomanufacturers increasingly require systems capable of handling smaller batch volumes with greater flexibility. SUS perfectly aligns with this trend through scalable architectures that support multiproduct facilities. The technology's closed processing environment provides inherent containment advantages for high-potency APIs being developed for targeted therapies. Recent case studies demonstrate that implementing single-use technologies can reduce cross-contamination risks by over 90% compared to traditional systems, making them ideal for facilities producing multiple cell and gene therapies simultaneously.

Regulatory Support for Advanced Manufacturing Technologies

Health authorities worldwide are actively encouraging the adoption of innovative bioprocessing technologies through regulatory harmonization initiatives. The most recent good manufacturing practice (GMP) guidelines explicitly recognize single-use systems as validated manufacturing platforms when properly implemented. This evolving regulatory landscape provides manufacturers with the confidence to transition from stainless steel to disposable technologies. Industry surveys indicate that regulatory certainty ranks among the top three factors influencing biopharma companies' technology adoption decisions.

➤ Leading contract manufacturers have reported 30-50% reductions in facility validation timelines when deploying single-use systems for new production lines, accelerating overall project ROI.

MARKET RESTRAINTS

Supply Chain Vulnerabilities Threatening Market Stability

The SUS market faces significant pressure from global polymer supply constraints that emerged during recent healthcare crises. With over 80% of single-use components relying on specialized plastic formulations, disruptions in raw material availability can delay critical manufacturing operations. The industry's dependence on single-source suppliers for key components like bioprocess containers creates bottleneck risks that deter larger-scale adoption. Some manufacturers report lead times extending to 9-12 months for customized SUS assemblies, prompting concerns about production planning reliability.

Extractables/Leachables Concerns Limiting High-Concentration Applications

While SUS technology has proven effective for most monoclonal antibody production, challenges persist with highly concentrated biologic formulations. Recent studies highlight potential interactions between sensitive drug substances and plasticizer compounds in single-use components. The absence of standardized extractables testing protocols across different resin formulations creates validation complexities. These technical hurdles currently restrict SUS adoption for certain high-value biotherapeutics requiring extreme purity specifications.

MARKET CHALLENGES

Sustainability Perceptions Impacting Adoption Decisions

The environmental impact of plastic waste generated by single-use technologies represents a growing reputational challenge. Although life cycle analyses demonstrate that SUS can reduce water and energy consumption by 60-70% versus traditional systems, the visible disposal of plastic components creates negative optics. Many biopharma companies face increasing pressure from ESG investors to demonstrate circular economy solutions for their manufacturing processes.

Other Challenges

Scale Limitations for Commercial Production
Current SUS configurations struggle to economically support commercial-scale production beyond 2,000-liter batches. The volumetric constraints force manufacturers to implement multiple parallel systems, increasing operational complexity. This limitation particularly impacts blockbuster biologics requiring high-volume output.

Workforce Training Gaps
The rapid evolution of SUS technologies has outpaced workforce training programs at many facilities. A recent industry survey revealed that 65% of bioprocessing professionals require additional hands-on training to maximize system utilization.

MARKET OPPORTUNITIES

Next-Gen Single-Use Components Opening New Applications

Material science breakthroughs are enabling a new generation of SUS products with enhanced performance characteristics. Novel polymer formulations now demonstrate improved chemical resistance for demanding applications like viral vector production. These advancements expand the technology's suitability for emerging modality manufacturing while reducing extractables-related risks. The membrane filtration segment alone is projected to grow at 28% CAGR through this innovation wave.

Emerging Markets Driving Infrastructure Modernization

Biopharma hubs in Asia and Latin America present significant growth opportunities as they transition from traditional to advanced manufacturing platforms. Governments in these regions are implementing favorable policies to attract biomanufacturing investments, with single-use technologies featuring prominently in new facility blueprints. The Asia-Pacific SUS market is projected to account for over 38% of global demand by 2027 as regional vaccine and biosimilar production scales up.

Digital Integration Creating Smart SUS Ecosystems

The convergence of single-use technologies with Industry 4.0 solutions represents a transformative opportunity. Embedded sensors in next-generation SUS components enable real-time monitoring of critical process parameters. When integrated with AI-powered analytics platforms, these smart systems can predict equipment performance issues before they impact product quality. Early adopters report 30% improvements in batch success rates through such digital implementations.

Segment Analysis:

By Type

Single-Use Bioreactors Lead the Market Due to Increased Demand in Biopharmaceutical Production

The market is segmented based on type into:

• Single-use bioreactors

  • Subtypes: Stirred-tank, wave-induced, and others

• Disposable sterile bags

• Disposable filtration systems

  • Subtypes: Depth filters, membrane filters, and others

• Others

By Application

Bio-Pharmacy Segment Dominates Due to Rapid Growth in Biologics Manufacturing

The market is segmented based on application into:

• Bio-pharmacy

• CDMO (Contract Development & Manufacturing Organizations)

• Academic and research institutions

• Others

By Material

Plastic-Based Systems Hold Majority Share Due to Cost-Effectiveness and Flexibility

The market is segmented based on material into:

• Plastic-based systems

  • Subtypes: Polyethylene, polypropylene, and others

• Polymer-based systems

• Others

By Scale

Large-Scale Operations Dominate Due to Commercial Biopharmaceutical Production Needs

The market is segmented based on scale into:

• Small-scale

• Medium-scale

• Large-scale

COMPETITIVE LANDSCAPE

Key Industry Players

Strategic Expansions and Product Innovations Drive Market Competition

The global SUS (Single Use System) for Biopharma Process market exhibits a competitive but concentrated structure, with the top five players collectively holding approximately 73% market share as of 2023. Dominance in this space requires substantial R&D capabilities, scalable manufacturing, and adaptability to evolving regulatory standards – factors that have allowed established players to maintain leadership positions while creating barriers for new entrants.

Leading the market is Danaher Corporation, whose acquisition strategy has significantly expanded its bioprocessing capabilities. Through its subsidiary Cytiva, the company offers an extensive portfolio including single-use bioreactors and filtration systems, with particular strength in North America and Europe where biopharmaceutical production is concentrated. Their 2023 revenue from single-use bioprocessing exceeded $1.8 billion, underlining market dominance.

Thermo Fisher Scientific follows closely, leveraging its vertical integration advantage. Their 2022 launch of the HyPerforma DynaDrive Single-Use Bioreactor series demonstrated innovative scale-up capabilities up to 5,000L, addressing a critical industry need for large-volume manufacturing. Their market position is further strengthened by comprehensive service offerings and global distribution networks.

The competitive landscape shows emerging regional players gaining traction – particularly in Asia-Pacific which holds 31% of the global market. Lepure China and Tofflon have doubled production capacity since 2021, capitalizing on local biopharma growth while offering cost-competitive alternatives. However, these companies face challenges in meeting stringent quality standards required for Western markets.

Meanwhile, European firm Sartorius has demonstrated aggressive expansion, with its bioprocess solutions division growing at 34% CAGR (2020-2023). Their recent collaboration with mRNA vaccine developers highlights the strategic focus on next-generation therapies. Similarly, Merck KGaA has invested over €500 million in single-use facility expansions since 2021, signaling long-term commitment to this technology.

List of Key SUS for Biopharma Process Companies Profiled

• Danaher Corporation (U.S.)

• Thermo Fisher Scientific (U.S.)

• Sartorius AG (Germany)

• Merck KGaA (Germany)

• Lepure China (China)

• JYSS Bio-Engineering (China)

• Tofflon (China)

• Duoning Biotechnology (China)

• ABEC (U.S.)

• AUSTAR (China)

SUS (SINGLE USE SYSTEM) FOR BIOPHARMA PROCESS MARKET TRENDS

Advancements in Bioprocessing Efficiency to Drive Single-Use System Adoption

The biopharmaceutical industry is witnessing a paradigm shift toward single-use systems (SUS) for manufacturing processes, driven by their ability to reduce cross-contamination risks and improve operational efficiency. With a projected market value of $18.9 billion by 2030, growing at a 21% CAGR, SUS technologies are transforming bioprocessing workflows. Recent innovations include advanced single-use bioreactors with improved scalability and sensor integration, enabling real-time monitoring of critical parameters like pH and dissolved oxygen. This technological evolution is particularly crucial for vaccine production and monoclonal antibody manufacturing, where flexibility and rapid turnaround times are paramount.

Other Trends

Sustainability-Driven Material Innovations

While single-use systems reduce water and energy consumption compared to stainless steel alternatives, the industry faces growing pressure to address plastic waste concerns. Leading manufacturers are responding with bio-based polymers and multi-layer film technologies that maintain sterility while improving recyclability. Approximately 32% of biopharma facilities now prioritize SUS solutions with reduced environmental impact, though this remains a complex challenge given stringent regulatory requirements for material compatibility and leachables testing.

Regional Market Diversification and Capacity Expansion

The geographical landscape for SUS adoption is evolving rapidly, with Asia-Pacific emerging as the fastest-growing region (31% market share) due to increasing biopharma outsourcing and government initiatives supporting domestic manufacturing. Contract development and manufacturing organizations (CDMOs) are particularly active in this shift, with over 45 new SUS-equipped facilities announced in the past two years across India and China. Meanwhile, established markets like North America and Europe maintain strong positions (32% share each) through continued investment in advanced therapy medicinal product (ATMP) production capabilities.

Regional Analysis: SUS (Single Use System) for Biopharma Process Market

North America
North America represents one of the largest markets for SUS in biopharma processes, capturing approximately 32% of global revenue share. The region's leadership stems from strong biopharmaceutical R&D investments, especially in biologics and cell/gene therapies. The U.S. FDA's progressive stance on flexible manufacturing approaches and regulatory guidelines for single-use technologies boosts adoption. Major pharmaceutical hubs like Boston and San Diego drive demand for disposable bioreactors and filtration systems due to the high concentration of biotech startups and CDMOs. However, supply chain vulnerabilities for raw materials like plastics challenge production scalability, prompting manufacturers to explore sustainable alternatives.

Europe
Europe holds an equal 32% market share alongside North America, supported by stringent EMA regulations favoring contamination-free manufacturing. Countries like Germany and Switzerland, home to giants like Merck and Sartorius, lead in SUS adoption for monoclonal antibody production. The EU's push for circular economy principles is accelerating innovations in recyclable polymer formulations, though material compatibility with sensitive biologics remains a technical hurdle. Post-pandemic vaccine manufacturing expansions have further catalyzed investments in single-use bioreactor systems, particularly in France and the UK, where modular facilities gain traction.

Asia-Pacific
Accounting for 31% of the global market, Asia-Pacific is the fastest-growing region, projected to outpace others with a CAGR exceeding 23% through 2030. China dominates with aggressive biopharma capacity expansions—its "Made in China 2025" initiative prioritizes domestic SUS solutions from firms like Lepure. India emerges as a key player too, leveraging cost advantages in biosimilars production. While price sensitivity initially favored stainless steel, rising labor costs and facility space constraints now drive single-use adoption. Japan and South Korea focus on advanced applications, including cell therapy production using single-use systems, though cultural preferences for traditional technologies linger.

South America
This nascent market shows potential but faces infrastructure limitations—Brazil leads with localized vaccine production initiatives leveraging SUS to bypass sterilization bottlenecks. Argentina's biotech sector, though small, demonstrates early adoption for insulin and recombinant proteins. Economic instability and import dependency for raw materials restrain broader market penetration. Nonetheless, regional alliances like Mercosur are fostering API manufacturing partnerships, indirectly benefiting SUS demand as regulators harmonize standards with international guidelines over time.

Middle East & Africa
Growth here remains aspirational but strategic—Saudi Arabia's Vision 2030 includes biopharma localization with single-use tech in Neom's planned biologics hub. South Africa pioneers with HIV vaccine research using disposable systems, supported by global health partnerships. However, limited cold chain logistics and fragmented regulations delay widespread adoption. The UAE shows promise with Dubai Science Park attracting CDMOs, though market maturity lags a decade behind other regions. As African vaccine manufacturing expands post-COVID, SUS could become pivotal for modular, rapid deployment facilities.

Report Scope

This market research report offers a holistic overview of global and regional markets for the forecast period 2025–2032. It presents accurate and actionable insights based on a blend of primary and secondary research.

Key Coverage Areas:

• ✅ Market Overview

  • Global and regional market size (historical & forecast)

  • Growth trends and value/volume projections

• ✅ Segmentation Analysis

  • By product type or category

  • By application or usage area

  • By end-user industry

  • By distribution channel (if applicable)

• ✅ Regional Insights

  • North America, Europe, Asia-Pacific, Latin America, Middle East & Africa

  • Country-level data for key markets

• ✅ Competitive Landscape

  • Company profiles and market share analysis

  • Key strategies: M&A, partnerships, expansions

  • Product portfolio and pricing strategies

• ✅ Technology & Innovation

  • Emerging technologies and R&D trends

  • Automation, digitalization, sustainability initiatives

  • Impact of AI, IoT, or other disruptors (where applicable)

• ✅ Market Dynamics

  • Key drivers supporting market growth

  • Restraints and potential risk factors

  • Supply chain trends and challenges

• ✅ Opportunities & Recommendations

  • High-growth segments

  • Investment hotspots

  • Strategic suggestions for stakeholders

• ✅ Stakeholder Insights

  • Target audience includes manufacturers, suppliers, distributors, investors, regulators, and policymakers

FREQUENTLY ASKED QUESTIONS:

What is the current market size of Global SUS (Single Use System) for Biopharma Process Market?

-> Global SUS (Single Use System) for Biopharma Process market was valued at USD 4,979 million in 2023 and is projected to reach USD 18,920 million by 2030.

Which key companies operate in Global SUS (Single Use System) for Biopharma Process Market?

-> Key players include Danaher, Thermo Fisher, Sartorius, Merck, and Lepure China, with the top five players holding about 73% market share.

What are the key growth drivers?

-> Key growth drivers include increasing biopharmaceutical production, cost-efficiency of single-use systems, and reduced contamination risks compared to traditional stainless-steel systems.

Which region dominates the market?

-> North America and Europe are the largest markets (32% share each), followed by Asia-Pacific (31%) which is emerging as the fastest-growing region.

What are the emerging trends?

-> Emerging trends include development of hybrid systems, increased automation, sustainable material innovation, and standardization initiatives to address environmental concerns.