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Related Concept Videos

Scale-Up Processes01:14

Scale-Up Processes

The scale-up of microbial fermentation processes is essential in industrial biotechnology, allowing the transition from laboratory-scale experiments to commercial-scale production while aiming to maintain product yield and quality. This process requires meticulous adjustment of equipment design, process parameters, and contamination control strategies to accommodate increasing culture volumes.At the laboratory scale, cultures are typically maintained in 1 to 10-liter glass or autoclavable...
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Upstream processing represents a critical phase in biomanufacturing, wherein biological systems such as microorganisms, mammalian cells, or insect cells are cultivated to produce therapeutic proteins, vaccines, enzymes, or other biologically derived products. This phase encompasses all steps from the selection and genetic manipulation of the production organism to the cultivation of cells in bioreactors under tightly controlled environmental conditions.Host Selection and Genetic OptimizationThe...
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Bioreactor Design and Operational System

Bioreactors are engineered vessels designed to cultivate microorganisms under controlled conditions for industrial bioprocessing. They maintain sterility and allow precise regulation of pH, temperature, oxygen, and nutrient levels to optimize microbial growth and metabolite production. Bioreactors range from small laboratory units of 1 liter to industrial systems holding up to 500,000 liters, though only about 75% of their volume is actively used for fermentation. The remaining headspace...
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Growth media provide essential nutrients that support cell growth and metabolism, thereby enhancing the yield of valuable products such as enzymes, antibiotics, and biomass. Designing an effective growth medium involves balancing all components to prevent nutrient limitations or toxic excesses, both of which can impair growth and reduce product yields.Composition of a Typical Growth MediumA typical growth medium contains carbon and nitrogen sources, salts, vitamins, trace elements, and...
Bioreactor Controls-III01:22

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Strain improvement is a foundational strategy in industrial microbiology aimed at maximizing microbial productivity, particularly because natural isolates typically yield commercially valuable products in very low concentrations. Although optimizing the culture medium and environmental conditions can improve yields, these adjustments are inherently limited by the organism’s genetic potential. As a result, the focus shifts toward genetic modifications to enhance biosynthetic capacity. The...
Bioreactor Controls-II01:18

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In aerobic fermentations, oxygen is vital for microbial growth and metabolite production. Since air comprises only about 20% oxygen and the gas is poorly soluble in water—just 9 ppm at 20°C—supplying sufficient oxygen becomes a critical challenge, especially in high-demand processes like yeast growth or citric acid production. Even a fully saturated broth may offer only a few seconds of oxygen availability.To address this, sterile or scrubbed air is introduced into the fermentor via a sparger...

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Generic Protocol for Optimization of Heterologous Protein Production Using Automated Microbioreactor Technology
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Ensuring Good Transferability from Pilot- to Large-Scale Optimized Biotech Bubble Column Designs.

Carolin Link1, Jason Bromley2, Michael Martin2

  • 1Institute of Biochemical Engineering, University of Stuttgart, Allmandring 31, 70569 Stuttgart, Germany.

Bioengineering (Basel, Switzerland)
|May 27, 2026
PubMed
Summary
This summary is machine-generated.

Scaling gas fermentation simulations from pilot to industrial scale shows design transferability. Enhancements at pilot scale improve performance, but scale-up requires careful consideration of gas velocity for optimal mass transfer.

Keywords:
bioreactor modelingcomputational fluid dynamicslattice Boltzmannscale-up

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Area of Science:

  • Biotechnology
  • Chemical Engineering
  • Process Simulation

Background:

  • Scaling up gas fermentation processes is costly and time-consuming.
  • Optimizing reactor geometry is crucial for efficient industrial biotechnology.

Purpose of the Study:

  • To evaluate the transferability of pilot-scale simulation findings to industrial-scale simulations.
  • To improve the efficiency of reactor geometry optimization in gas fermentation.

Main Methods:

  • Computational fluid dynamics (CFD) simulations were performed at pilot (950 L) and industrial (950 m³) scales.
  • Geometric ratios and aeration rates (vvm) were kept constant initially, then superficial gas velocity was enforced.

Main Results:

  • Similar flow patterns were observed between scales, especially in airlift reactors.
  • Pilot-scale design improvements transferred to industrial scale, increasing kLa by up to 17%.
  • Constant superficial gas velocity enhanced transferability, yielding similar CO transfer rates and regime distributions.

Conclusions:

  • Reactor design enhancements are transferable across scales in gas fermentation.
  • Enforcing constant superficial gas velocity improves simulation transferability but may challenge industrial mass transfer requirements.