Discover how choosing the right bioreactor in the laboratory facilitates the scaling up of biotechnology processes to large-scale industrial production.
Bioreactors are a fundamental part of the biotechnology industry, both in the development of new processes and in their subsequent scaling up and production.
However, when we think of a large-capacity industrial bioreactor, it’s easy to focus solely on the most striking figure: the number of liters. Behind such a large-scale piece of equipment lies something much more important: a process that has had to be studied, controlled, optimized, and scaled up beforehand.
At Techmi Group, we design and manufacture bioreactors to support the various stages of this process, ranging from equipment for laboratories and R&D, to pilot-plant solutions, and large-capacity industrial bioreactors.
The road to large-scale production is a long one, but with the right equipment for the research phase, it becomes easier.
The path to industrial production begins in the laboratory
The research or laboratory phase is the stage at which much of the knowledge is gained that will later enable the process to be developed on a larger scale.
This is where the behavior of the culture is studied and critical parameters such as temperature, pH, dissolved oxygen (DO), agitation, and aeration—among others—are established.
For this reason, choosing good equipment from the very beginning should not be viewed solely as a laboratory necessity. It is a decision that can have an impact on the subsequent phases of the project.
A bioreactor that allows for the proper control, monitoring, and replication of process conditions provides more valuable information for subsequent scale-up.
What does it mean to escalate a process, and what is the correct way to do it?
As the volume increases, new challenges arise related to oxygen transfer, culture homogeneity, heat transfer, agitation, aeration, and the control of process variables.
For this reason, scaling should be approached gradually.
Laboratory → Pilot Plant → Industrial Production
Each of these stages provides information that helps define the conditions necessary for the next scale-up and reduce uncertainties before reaching industrial production.
Why is it important to maintain a philosophy of control between flights?
One of the aspects we pay particular attention to in our bioreactors is scale-up.
Working in the laboratory with variables, control strategies, and automation systems that can later be scaled up to larger-capacity equipment facilitates the transfer of knowledge acquired during development.
In Techmi bioreactors, we can integrate control of variables such as:
- Temperature
- pH
- Dissolved oxygen (DO)
- Agitation
- Aeration
- Feeding
- Defoamer
- Level and pressure, depending on configuration
In addition, PLCs, HMIs, data logging, recipes, automation, and SCADA systems may be included, depending on the project’s needs and scale.
The goal is not for a process to behave exactly the same way in a small reactor as it does in an industrial one—because physical conditions change with scale—but rather to have sufficient information, control, and adaptability to make that transition in an informed manner.
When the process reaches industrial scale
When dealing with large volumes, the design of the equipment becomes even more important.
Materials, geometry, agitation system, heat transfer, aeration, instrumentation, automation, cleaning and sterilization options, and integration with the rest of the plant are factors that must be evaluated based on the specific process.
At Techmi, we develop large-capacity industrial bioreactors, designed to meet specific production requirements.
On this scale, the bioreactor ceases to be an isolated component and becomes part of an industrial system that must integrate auxiliary equipment, piping, utilities, automation, and the various upstream and downstream stages of the process.
The Benefits of Working on Scaling with Techmi
Our philosophy is based on understanding the process first and then putting together the team.
This allows us to work on various aspects of the project: process engineering, bioreactor selection and sizing, manufacturing, automation, integration, installation, and commissioning.
Furthermore, having solutions for different scales makes it possible to develop a coherent technological roadmap:
Develop → validate → scale → produce
From a bioreactor used for experimental development to industrial-scale equipment holding thousands of liters, the goal is for each stage to contribute knowledge to the next.
Good laboratory equipment is also an investment in future production
In biotechnology, considering industrial production from the earliest stages can make a significant difference.
Selecting a bioreactor based solely on the laboratory’s immediate needs may later limit the information available for scaling up. In contrast, working from the outset with equipment that allows for proper control of critical variables, recording of process data, and reproduction of culture conditions builds a more solid foundation for continued growth.
That’s why, when we talk about our larger-capacity bioreactors, we’re also talking about our smaller units.
Because an industrial scale bioreactor isn’t the start of the process—it’s the result of everything we’ve learned before reaching that point.
At Techmi Group, we develop solutions to support that journey, from the initial testing phase through to industrial production.
Are you developing a new bioprocess or do you need to scale up an existing production process? Our team can help you identify the right solution for each stage of the project.