Commercialization of a novel fermentation concept.

Area of Science:

• Biotechnology
• Biochemical Engineering
• Industrial Microbiology

Background:

• Solid substrate fermentation (SSF) traditionally used in East Asia for food products.
• Submerged fermentation (SmF) became dominant in the West for antibiotics and enzymes due to automation and scalability.
• Biocon India initially utilized SSF for cost-effective specialty enzyme production.

Purpose of the Study:

• To overcome limitations of traditional SSF for sophisticated biotechnology products and large-scale fermentation.
• To develop a novel bioreactor for SSF with automation and containment comparable to SmF.
• To introduce advanced features like fed-batch fermentation and in situ extraction.

Main Methods:

• An 8-year research and development program to create a novel bioreactor.
• Development of the "PlaFractor" bioreactor for solid substrate fermentation.
• Focus on scale-up and commercialization processes for the new technology.

Main Results:

• Successful development of the PlaFractor bioreactor enabling automated and contained SSF.
• Incorporation of fed-batch fermentation and in situ extraction capabilities.
• Demonstrated potential for cost-effective, high-standard production of biotechnological products.

Conclusions:

• The PlaFractor technology represents a significant advancement in solid substrate fermentation.
• It offers a viable, scalable, and automated alternative to submerged fermentation for various applications.
• Biocon India's focus on commercially viable, globally competitive innovation is evident.