Single-Use Bioprocessing Probes and Sensors Market Size & Share Analysis - Growth Trends & Forecasts (2025 - 2030)

Single-Use Bioprocessing Probes And Sensors Market Analysis

The Single-Use Bioprocessing Probes And Sensors Market size is estimated at USD 3.84 billion in 2025, and is expected to reach USD 6.52 billion by 2030, at a CAGR of 11.2% during the forecast period (2025-2030).

The single-use bioprocessing probes and sensors industry has undergone significant transformation as biopharmaceutical manufacturers increasingly adopt advanced manufacturing technologies. According to data published by the American Pharmaceutical Review in April 2023, the adoption of commercial-scale single-use bioprocessing systems has shown remarkable growth, increasing from 32.5% in 2019 to 43% in 2022, indicating a broader industry shift toward flexible manufacturing solutions. This transition reflects the industry's growing emphasis on operational efficiency, reduced contamination risks, and enhanced production flexibility. The integration of these technologies has revolutionized traditional manufacturing processes, enabling faster product changeovers and reducing cleaning validation requirements.

Technological advancements in sensor design and capabilities have significantly enhanced the precision and reliability of bioprocessing operations. Modern single-use bioreactor sensors now incorporate features such as pre-calibration, gamma stability, and enhanced shelf life, making them increasingly attractive for biopharmaceutical manufacturing. These innovations have particularly benefited small and medium-scale manufacturing facilities, enabling them to maintain high-quality standards while optimizing operational costs. The industry has witnessed a notable shift toward integrated sensor solutions that offer real-time monitoring capabilities and improved process control.

Global facility expansions and infrastructure developments have characterized the market landscape throughout 2023. In June 2023, Avantor Inc. inaugurated its expanded Singapore Hub, which includes newly added CGMP manufacturing and a world-class quality control laboratory, strengthening the region's innovation and biopharma ecosystems. Similarly, Lonza's investment of CHF 200 million in July 2023 to add capacity for eight 2,000-L single-use bioreactors demonstrates the industry's commitment to expanding single-use capabilities. These developments reflect the growing global demand for single-use bioprocessing solutions and the industry's response to meet these needs.

The market has experienced a notable shift in manufacturing strategies, with companies increasingly adopting hybrid approaches that combine traditional and single-use technologies. This evolution has been particularly evident in the development of new manufacturing facilities, where flexibility and scalability are paramount considerations. The industry has witnessed increased collaboration between sensor manufacturers and bioprocessing equipment providers to develop integrated solutions that optimize process efficiency and product quality. These partnerships have resulted in more sophisticated sensor technologies that better meet the specific needs of different bioprocessing applications, from upstream cell culture to downstream purification processes.

Single-Use Bioprocessing Probes And Sensors Market Trends

Commercial Advantages Over Stainless Steel Bioprocessing Products

Single-use bioprocessing products offer significant commercial advantages over traditional stainless steel equipment, particularly in terms of operational efficiency and cost-effectiveness. These systems enable manufacturers to produce multiple different biopharmaceutical products in specific quantities while eliminating several process steps, thereby increasing drug production rates. The flexibility of single-use systems allows rapid scaling and efficient changes between campaigns without lowering plant capacity utilization, making them ideal for companies with yearly production demands of approximately 500 kg or less. Additionally, single-use bioprocessing products enable seamless process portability from one plant to another with minimal or no adaptation requirements, providing operational versatility that stainless steel systems cannot match. The integration of single-use bioreactor sensors further enhances the functionality and precision of these systems.

Traditional production with stainless steel equipment generally involves substantially higher expenses and requires extensive maintenance for reuse, resulting in elevated operational expenditures over several years. Single-use equipment revolutionizes biomanufacturing process steps by making processes more cost-effective through simplification and customization of bioprocessing technology. These systems eliminate the need for additional investment in complex production stages like cleaning and sterilization, thereby saving both costs and resources. Furthermore, with advances in biomanufacturing processes and the introduction of new types of bioreactor configurations, single-use bioprocessing equipment has reduced the need for sophisticated control systems, thus decreasing the costs associated with maintenance of the products. The adoption of single-use bioreactor sensors is a testament to the industry's move towards more efficient and precise bioprocessing solutions.

Rising Investment for Single-Use Bioprocessing Facility Expansion

The bioprocessing industry is witnessing substantial investments in expanding single-use facilities, driven by competing production priorities and the complex manufacturing requirements of biologics. In February 2022, Thermo Fisher Scientific demonstrated this trend by investing USD 40 million to expand its single-use bioprocessing technology manufacturing facility in Millersburg, Pennsylvania. This expansion was part of a larger USD 650 million multi-year investment to enhance the company's ability to provide flexible, scalable, and reliable single-use bioprocessing production capacity. The facility's expansion included modernizing warehouse space, cleaning rooms, and the addition of a new 47,000-square-foot warehouse, showcasing the industry's commitment to advancing single-use technology capabilities.

The investment momentum continues across various regions, with multiple companies expanding their single-use bioprocessing facilities. For instance, in October 2022, India-based PharmNXT Biotech launched its first integrated manufacturing unit in Pune, establishing a 40,000-square-foot production facility known as PharmNXT Ekuse to address the challenges of biologics manufacturing. Similarly, Merck KGaA made a significant investment of EUR 100 million in April 2022 to expand its first Asia-Pacific Mobius Single-Use manufacturing center in China, aiming to accelerate single-use bioprocessing capabilities for developing vaccines and therapeutics. These investments reflect the industry's recognition of single-use technology's crucial role in advancing biopharmaceutical manufacturing and meeting growing market demands. The single-use bioprocessing probes and sensors market is poised to benefit from these expansions, as the demand for precise and reliable monitoring solutions grows.

Segment Analysis: By Type

pH Sensor Segment in Single-Use Bioprocessing Probes and Sensors Market

The pH sensor segment continues to dominate the single-use bioprocessing probes and sensors market, commanding approximately 21% market share in 2024. This significant market position is attributed to rising technological advancements in pH sensors and their critical role in maintaining optimal conditions during bioprocessing operations. These sensors are extensively deployed in upstream and downstream bioprocess applications, including media mixing, buffer preparations, and large-scale cell culture. The segment's prominence is further reinforced by the sensors' ability to provide quality and accuracy for bioprocess single-use applications, making them indispensable in modern biopharmaceutical manufacturing processes.

Oxygen Sensor Segment in Single-Use Bioprocessing Probes and Sensors Market

The oxygen sensor segment is emerging as the fastest-growing category in the market, projected to expand at approximately a 12% growth rate from 2024 to 2029. This robust growth is driven by the increasing adoption of optical technology in single-use oxygen sensors, which enables fast and accurate dissolved oxygen measurements in bioprocessing applications. The segment's growth is further propelled by the significant technical advantages these sensors offer in measuring O2 and CO2 concentrations in bioprocesses using in-situ disposable sensors. The optimization capabilities in bioreactor processes and the rising demand for sophisticated control systems in bioprocessing applications are also contributing to the segment's accelerated growth trajectory.

Remaining Segments in Single-Use Bioprocessing Probes and Sensors Market

The market encompasses several other crucial segments, including pressure sensors, temperature sensors, conductivity sensors, and flow meters and sensors, each serving specific functions in bioprocessing applications. Pressure sensors play a vital role in preventing over-pressurization and monitoring bioreactor performance, while temperature sensors ensure precise temperature control critical for cell health and productivity. Conductivity sensors are essential for monitoring and controlling various parameters in bioprocessing systems, and flow meters provide accurate measurement of fluid transfer in bioprocessing applications. These segments collectively contribute to the comprehensive monitoring and control capabilities required in modern bioprocessing operations, ensuring optimal production conditions and product quality.

Segment Analysis: By Workflow

Upstream Segment in Single-Use Bioprocessing Probes and Sensors Market

The upstream segment dominates the single-use bioprocessing probes and sensors market, commanding approximately 72% of the market share in 2024. This significant market position is primarily driven by the extensive use of single-use probes and sensors in critical upstream bioprocessing applications such as cell culture, fermentation, and microorganism cultivation. The segment's dominance is further strengthened by the increasing adoption of single-use technologies in biopharmaceutical manufacturing, particularly in processes aimed at optimizing cell growth and productivity. Key factors contributing to this segment's leadership include the rising demand for process optimization in cell culture applications, the growing need for contamination control in upstream bioprocessing, and the expanding biopharmaceutical industry through investments and research activities. The segment's robust performance is also supported by the increasing implementation of single-use sensors for monitoring various parameters like pH, temperature, and oxygen levels during upstream processing stages.

Downstream Segment in Single-Use Bioprocessing Probes and Sensors Market

The downstream segment is emerging as the fastest-growing segment in the single-use bioprocessing probes and sensors market, projected to grow at approximately 12% during the forecast period 2024-2029. This accelerated growth is primarily attributed to the increasing adoption of single-use technologies in downstream processing applications such as filtration, chromatography, and purification processes. The segment's rapid expansion is driven by the growing emphasis on product quality and purity in biopharmaceutical manufacturing, coupled with the rising demand for efficient and cost-effective downstream processing solutions. The integration of advanced sensor technologies in downstream applications, particularly in processes involving product isolation and purification, is further accelerating segment growth. Additionally, the increasing focus on process analytical technology (PAT) in downstream bioprocessing and the rising demand for real-time monitoring solutions are contributing to the segment's robust growth trajectory.

Segment Analysis: By End User

Biopharmaceutical Manufacturers Segment in Single-Use Bioprocessing Probes and Sensors Market

The biopharmaceutical manufacturers segment continues to dominate the single-use bioprocessing probes and sensors market, holding approximately 42% market share in 2024. This significant market position is primarily driven by the growing investments in research, development, and production of biopharmaceuticals by these companies. The segment's dominance is further strengthened by the increasing adoption of single-use technologies in biopharmaceutical manufacturing processes, which offer advantages such as reduced contamination risks and improved operational efficiency. Major biopharmaceutical manufacturers are actively expanding their facilities and incorporating single-use technologies, particularly in vaccine and cell therapy production. The segment's robust growth is also supported by the rising demand for biologics and biosimilars, compelling manufacturers to enhance their production capabilities through advanced bioprocessing technologies.

CMOs and CROs Segment in Single-Use Bioprocessing Probes and Sensors Market

The Contract Manufacturing Organizations (CMOs) and Contract Research Organizations (CROs) segment is projected to exhibit the highest growth rate of approximately 12% during the forecast period 2024-2029. This accelerated growth is attributed to the increasing trend of outsourcing biopharmaceutical research, development, and production activities to reduce overall costs. The segment's expansion is further fueled by the rising number of collaborations between biopharmaceutical companies and CMOs/CROs, particularly for developing novel biologics and biosimilars. These organizations are increasingly investing in expanding their capabilities and adopting single-use technologies to support the growing demands of biopharmaceutical companies seeking their services. The flexibility and cost-effectiveness offered by single-use bioreactor sensors make them particularly attractive for CMOs and CROs, who need to handle multiple projects with different requirements.

Remaining Segments in Single-Use Bioprocessing Probes and Sensors Market

The other end users segment, which primarily includes research and academic institutes, plays a crucial role in advancing the single-use bioprocessing probes and sensors industry. These institutions contribute significantly to scientific discovery, innovation, and the advancement of novel therapies through their fundamental research activities. Research and academic institutes often collaborate with biopharmaceutical companies for technology transfer, expertise sharing, and joint research initiatives, which drives the adoption of single-use bioprocessing technologies. Their involvement in various clinical trials and research projects necessitates the use of advanced bioprocessing equipment, including single-use bioreactor sensors, making them an important consumer segment in the market.

Single-Use Bioprocessing Probes And Sensors Market Geography Segment Analysis

Single-Use Bioprocessing Probes and Sensors Market in North America

North America represents a dominant force in the single-use bioprocessing probes and sensors market, driven by its well-established biopharmaceutical sector and widespread adoption of single-use technologies. The region benefits from the presence of major market players, robust research and development infrastructure, and increasing investments in bioprocessing facilities. The United States leads the regional market, followed by Canada and Mexico, with all three countries showing significant advancement in biopharmaceutical manufacturing capabilities and adoption of single-use technologies.

Single-Use Bioprocessing Probes and Sensors Market in United States

The United States maintains its position as the largest market for single-use bioprocessing probes and sensors in North America, holding approximately 87% of the regional market share. The country's dominance is attributed to its well-established biopharmaceutical sector, extensive research and development activities, and strong presence of major market players. The market benefits from increasing support from government agencies for bioprocessing development and rising adoption of single-use technologies across various biopharmaceutical applications. The country's leadership is further strengthened by continuous technological advancements and strategic expansions by key industry players in the single-use bioprocessing segment.

Single-Use Bioprocessing Probes and Sensors Market Growth Trajectory in United States

The United States also leads in terms of market growth, with a projected CAGR of approximately 11% from 2024 to 2029. This growth is driven by increasing investments in biopharmaceutical production facilities, rising adoption of single-use bioreactor sensors, and expanding research and development activities. The country's robust healthcare infrastructure, coupled with growing demand for biopharmaceuticals, continues to drive innovation in single-use bioprocessing technologies. The market expansion is further supported by strategic initiatives from key industry players and an increasing focus on developing cost-effective and efficient bioprocessing solutions.

Single-Use Bioprocessing Probes and Sensors Market in Europe

Europe represents a significant market for single-use bioprocessing probes and sensors, characterized by strong research and development capabilities and increasing adoption of advanced bioprocessing technologies. The region's market is driven by well-established pharmaceutical and biotechnology sectors across countries including the United Kingdom, Germany, France, Italy, and Spain. The presence of major market players, coupled with increasing investments in biopharmaceutical research and manufacturing facilities, continues to strengthen the region's position in the global market.

Single-Use Bioprocessing Probes and Sensors Market in United Kingdom

The United Kingdom emerges as the largest market for single-use bioprocessing probes and sensors in Europe, commanding approximately 23% of the regional market share. The country's leadership position is supported by its robust healthcare infrastructure, significant investments in life sciences, and a strong focus on biopharmaceutical research and development. The UK market benefits from government initiatives supporting bioprocessing development and the presence of world-class research institutions and biopharmaceutical companies.

Single-Use Bioprocessing Probes and Sensors Market Growth Trajectory in France

France demonstrates the highest growth potential in the European market, with a projected CAGR of approximately 12% from 2024 to 2029. The country's impressive growth trajectory is driven by increasing investments in bioprocessing facilities, rising adoption of single-use technologies, and strong government support for biotechnology research. France's commitment to developing its biopharmaceutical manufacturing capabilities, coupled with strategic expansions by key industry players, positions it as a rapidly evolving market in the region.

Single-Use Bioprocessing Probes and Sensors Market in Asia-Pacific

The Asia-Pacific region represents a rapidly evolving market for single-use bioprocessing probes and sensors, characterized by increasing investments in biopharmaceutical manufacturing and growing adoption of single-use technologies. The region encompasses key markets including China, Japan, India, Australia, and South Korea, each contributing significantly to the market's growth. The expansion of bioprocessing facilities, coupled with rising demand for biopharmaceuticals, drives the market's development across the region.

Single-Use Bioprocessing Probes and Sensors Market in China

China emerges as the largest market for single-use bioprocessing probes and sensors in the Asia-Pacific region. The country's dominance is attributed to its expanding biopharmaceutical sector, increasing investments in bioprocessing facilities, and growing adoption of single-use technologies. China's market leadership is supported by government initiatives promoting biotechnology development, the presence of major manufacturing facilities, and rising demand for biopharmaceutical products.

Single-Use Bioprocessing Probes and Sensors Market Growth Trajectory in India

India demonstrates exceptional growth potential in the Asia-Pacific region's single-use bioprocessing probes and sensors market. The country's market expansion is driven by increasing investments in bioprocessing facilities, growing adoption of single-use technologies, and a rising focus on biopharmaceutical manufacturing. India's emergence as a key player is supported by its strong pharmaceutical manufacturing base, government initiatives promoting biotechnology, and increasing research and development activities.

Single-Use Bioprocessing Probes and Sensors Market in Middle East & Africa

The Middle East & Africa region shows promising development in the single-use bioprocessing probes and sensors market, with GCC countries and South Africa leading the regional growth. The market benefits from increasing investments in healthcare infrastructure and rising adoption of advanced bioprocessing technologies. Among the countries in this region, GCC emerges as the largest market, while South Africa demonstrates the fastest growth potential, driven by expanding research and development activities and an increasing focus on biopharmaceutical manufacturing capabilities.

Single-Use Bioprocessing Probes and Sensors Market in South America

The South American market for single-use bioprocessing probes and sensors continues to evolve, with Brazil and Argentina emerging as key contributors to regional growth. The market is characterized by increasing investments in biopharmaceutical manufacturing facilities and growing adoption of single-use technologies. Brazil establishes itself as the largest market in the region, while also demonstrating the fastest growth potential, supported by expanding research and development activities and rising demand for biopharmaceutical products.