Microbial production is at the heart of modern biotechnological processes. Scaling up fermentation from the laboratory scale to industrial production is a complex but crucial task for businesses. BRAIN Biotech offers extensive expertise and facilities to support companies in this process. This article provides an insight into their approach and services for microbial fermentation scale-up.
Fermentation is a fundamental biotechnological process in which microorganisms convert substrates into valuable products under controlled conditions. At BRAIN Biotech, fermentation is precisely designed to optimize microbial growth and maximize product yields.
At the Zwingenberg site, fermentation processes are carefully planned to provide the optimal environment for microbial growth. Scientists and engineers gather detailed information on the specific requirements of each strain, such as nutrient preferences, pH levels and oxygen needs.
Initial experiments are conducted in small-scale fermenters, typically 2 liters, to optimize conditions. After optimization, the process is transferred to larger reactors and scaled up to volumes as large as 200 liters. This step-by-step scaling approach allows the process to be refined before reaching full production scale.
BRAIN Biotech uses different fermentation processes depending on the production requirements:
Scaling fermentation from laboratory to industrial level presents several challenges. In small-scale fermenters, stirring rates can be very high, providing excellent mixing and oxygenation. In large-scale fermenters, however, the power input is much lower, which affects both mixing and oxygen distribution. Industrial fermenters also introduce complexities in cooling and sterilization. Despite these challenges, both laboratory and industrial fermenters are equipped with similar sensors, ensuring the collection of comparable data.
Scaling up from the lab to industrial production requires careful process transfer. At BRAIN Biotech, processes are first developed on small scale, typically between 1 and 10 liters, and then scaled up to 200 liters. For larger production volumes, the processes are transferred to partners within the BRAIN Biotech Group, such as the BRAIN Biotech Group company Biocatalysts Ltd, where reactors with capacities of up to 10,000 liters are used.
The scaling process requires meticulous adjustments and constant communication between teams. Differences in equipment, such as filtration systems or media preparation methods, can lead to variations in yield. Therefore, BRAIN Biotech conducts additional experiments to refine the process for the specific requirements of the production facility.
Technical differences between laboratory and industrial settings pose unique challenges when scaling up. For example, the use of different cell separation techniques or changes in media components can affect the yield or efficiency of the process. These issues necessitate ongoing collaboration between the teams to ensure that partners are aligned on the established process. Fine-tuning the production method is critical, and the process must be adjusted to fit the partner's equipment and capabilities. Communication is essential throughout this technology transfer to ensure a smooth translation from laboratory-scale processes to large-scale industrial production.
There are several exciting trends in the future of microbial fermentation. Single-use bioreactors are becoming increasingly popular, especially in pharmaceutical biotechnology. These disposable reactors eliminate the need for complex cleaning and sterilization, reducing the risk of cross-contamination and improving process safety. Another emerging trend is precision fermentation, which focuses on the microbial production of specific functional ingredients including food proteins. This technology has the potential to revolutionize industries such as food production, where sustainable alternatives to traditional animal farming are gaining in importance.
BRAIN Biotech provides comprehensive services for scaling microbial fermentation from the laboratory to industrial production. Its structured approach, technical expertise and ability to adapt processes to different production scales ensure efficient and reliable microbial production. With growing trends like precision fermentation, BRAIN Biotech remains at the forefront of biotechnological innovation, offering solutions that meet both current and future industry needs.
