Todd Vaughn and Christa Myers on What Robotics Mean for Pharma Manufacturing

Access Part 1 of this interview on rising automation in aseptic manufacturing and growing regulatory focus on sterility.

In Part 2 of a two-part interview at INTERPHEX 2026, Todd Vaughn and Christa Myers, Fellows of Aseptic and Sterile Products at CRB, speak with PharmTech to discuss their panel discussion on the growing role of robotics and automation within the aseptic core of pharmaceutical manufacturing. Their conversation covers where the industry stands today, the opportunities automation presents, and what challenges lie ahead.

Both speakers highlight environmental monitoring, specifically, the automated handling of plates and monitors. As Myers notes, "Every time you stick your hand in a glove to change a plate, which sometimes happens every hour, sometimes happens every two hours, you have to stop your fill line, which means you have to stop production, which means you have to stop manufacturing." Automating this step, she argues, could significantly restore efficiency to fill lines and should have been done years ago.

Beyond environmental monitoring, both emphasize the value of robotics in equipment setup and component handling, citing improved repeatability and reduced reliance on human consistency. However, they are clear that automation doesn't mean fewer people; it means different people with different skills. Operators will need deeper technical knowledge, including mechanical and electronics training, while upstream areas like component prep and sterilization may actually require more staff.

Regulatory expectations are also shifting. As Todd Vaughn states, "Continuous improvement is what's expected now" and operators must be prepared to track trends and demonstrate risk mitigation when regulators come calling. Looking ahead, Vaughn describes the industry as being "right on the edge of novel use to expected use," anticipating that older lines could soon face scrutiny as fully automated systems become the new standard. Vaughn and Myers stress that the industry must also find ways to bring smaller, less-capitalized companies along for this transition, because their contributions to patients remain just as vital.