News & Insights
In a recent industry presentation to cell therapy professionals, we asked the audience, “What scientific or technical challenge most impacts your program today?” Overwhelmingly, the answer was managing the timeline to IND.
This sentiment is unsurprising given the scientific competition for first-in-class status and a tight capital investment environment. Since IND submission is typically the first significant value-inflection milestone, every month spent in preclinical development utilizes financial resources without meaningfully raising an asset’s valuation. As a result, prolonged preclinical development jeopardizes milestone-based funding, often risking the program itself.
Additionally, key patents are typically filed well before a cell therapy IND submission. Preclinical delays shorten the value-producing life of various patentable constructs, such as novel targets, cell constructs, methods, delivery systems, etc.
Finally, and arguably, the most crucial reason cell therapy developers strive to expedite their path to the clinic is that patients are waiting. Many cell therapies target high-mortality or chronically debilitating diseases with no alternatives. Delays mean prolonged unmet need.
Cell Therapy IND Timeline Risks & How to Avoid Them
Numerous factors jeopardize successful cell therapy IND filings or extend the preclinical development timeline beyond the planned period. This article explores manufacturability, raw material and cell source variability, and the lack of early process characterization. Additionally, we discuss courses of action to mitigate these challenges, allowing innovators to keep their programs on track.
Challenge: Manufacturability
While research and development are commonly uttered in a single breath, these functions have very different goals. Researchers generate new scientific knowledge, identify a therapeutic concept that might work, and seek proof of concept, assuring that the therapy effectively modifies disease pathways. On the other hand, developers work to transform the concept into a reproducible, safe, and compliant product that succeeds in clinical trials and, ultimately, in the market. While research teams are looking to understand and exploit or circumvent the biology of a particular indication, the development team is looking to deploy technology to ensure that solutions can be brought to patients in a reliable and reproducible manner.
The tension between research and development manifests when a construct displays promising therapeutic performance but proves difficult or even impossible to manufacture and scale reliably, consistently, and cost-effectively. However, conducting manufacturability assessments helps to avoid advancing candidates that are not practical or possible to produce.
Solution: Manufacturability Assessments
A manufacturability assessment is an early, cross-functional exploration that asks whether a promising cell therapy can be produced reliably, economically, and in full regulatory compliance. Process engineers map each unit operation—from cell isolation and genetic modification to harvest, fill-finish, and storage—flagging scale-up bottlenecks and other areas of challenge.
Additionally, quality, analytical, and regulatory specialists evaluate raw material sourcing, product safety strategies, and needed analytical characterization and testing. Supply chain teams explore the availability of key reagents and donor material, as well as strategies to ensure the appropriate chain of identity and chain of custody are intact (if the starting material comes from a patient). The outcome is a thorough summary of gaps and risks, cost-of-goods modeling, and a phase-appropriate plan to transform the promising research into an executable CMC roadmap.
Early identification of risks and gaps needing to be addressed avoids costly rework that can add months to an IND filing preparation. While not a desired outcome, manufacturability assessments may reveal that a candidate cannot be produced in a manner that would achieve defined commercial objectives. Early abandonment of a program that will not work saves capital and allows time and financial resources to be applied to other possibilities.
Challenge: Raw Material and Cell Source Variability
Raw material and cell source variability are often identified as costly delays in cell therapy development. Every cell therapy input carries an invisible fingerprint of biological or manufacturing noise. Even subtle lot-to-lot shifts in purity or trace endotoxin can impact Critical Quality Attributes (CQAs) and nudge a product from its Quality Target Product Profile (QTPP)—the ripple effects compound as a program advances. This is especially true when developing immune cell therapies, which have evolved to be more sensitive to microbial impacts (e.g., as a natural result of their function in the immune system). For example, early proof-of-concept data generated with research-grade reagents may prove irreproducible when those reagents are swapped for GMP equivalents, forcing repeat studies that add months and consume precious patient samples and company resources.
Donor variability magnifies the challenge. Autologous therapies depend on starting material collected from patients whose disease state, prior treatments, and individual biology influence cell phenotype. Cell variability can also impact allogeneic programs as multiple health donor or master cell banks derived from primary cell sources need to be changed. These inconsistencies manifest downstream as unpredictable expansion kinetics, batch-to-batch potency swings, and comparability challenges.
Solution: Well-Defined Supply Chain Strategies & Donor Screening
Developers must lock raw material specifications early, qualify secondary suppliers, and establish release assays that read out functional rather than merely compositional endpoints. For starting cells, tight donor-screening algorithms, collection SOPs, and real-time phenotyping help to protect the process. Layering Design of Experiments (DoE) studies onto process development clarifies the acceptable ranges of input variation and builds statistical confidence in batch release criteria. Without establishing these strategies and controls, the risks of significant program setbacks substantially increase as development progresses.
Challenge: Lack of Early, Robust Cell Therapy Process Characterization
Failing to thoroughly characterize a cell therapy process early sets off a chain reaction of technical and regulatory difficulties that are challenging to rectify. Without data-driven insight into how each unit operation behaves, critical parameters drift from loosely defined values in the lab to poorly controlled targets in GMP production. Unfortunately, repercussions generally grow with scale.
Ineffective cell therapy process characterization can naturally lead to IND filing challenges. Without a thorough understanding of how the process impacts CQAs and, ultimately, the QTPP, process developers lack the insights to justify process decisions and changes to regulators, possibly forcing costly and time-consuming additional comparability runs. The quality team could be equally challenged, as it is difficult to defend product-release criteria without strategically established CQAs. Importantly, this also ensures that robust assays are developed early to truly understand the biology that process optimizations impact particular unit operations.
Solution: Well-Defined TPP
Developers can best address these risks by defining a TPP early and running structured DoE studies to map critical process parameters and set understood and defensible operating ranges. They should also standardize raw and starting materials, qualify GMP-grade suppliers of key reagents, secure secondary suppliers, and establish functional release assays that flag relevant lot variation and drive process consistency. Finally, innovators should strategically utilize pre-IND meetings with regulators to discuss and secure alignment on process control and quality assurance plans.
Navigating Cell Therapy IND Timeline Risks: How Kincell Bio Guides Programs Toward Success
In this article, we’ve highlighted cell therapy developers’ leading technical risks on the path to IND submission—risks that can derail timelines, exhaust capital, and jeopardize patient impact. Chief among these are manufacturability challenges, raw material and cell source variability, and insufficient early cell therapy process characterization.
Promising constructs often falter when scaled, as manufacturability issues surface too late or supply chains introduce variability that compromises reproducibility. Without early, robust process characterization, developers face technical and regulatory hurdles that slow progress and increase costs. Kincell Bio addresses these risks by performing manufacturability assessments, establishing well-defined supply chain and donor strategies, and designing early, data-driven process characterization plans to build a phase-appropriate, scalable, and regulatory-compliant development roadmap.
As a cell therapy CDMO partner, Kincell offers expertise to translate scientific discovery into clinical-grade products, helping clients navigate complex IND timelines.
Please get in touch with us if we can help support your current cell therapy program.
