An integrated approach is described for accelerating process development workflows. The approach involves five strategies which include increased mechanistic understanding, process intensification, and plug-and-play modules with integrated control and monitoring. Automated high-throughput microscale technologies are described for process research and development. Deployment is facilitated by accompanying each physical modular system with a dynamic mechanistic model. A process data analytics strategy is described in which the best methods are automatically selected based on the data characteristics and user objectives. The strategies are illustrated in applications to vaccine manufacturing systems.
