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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...
Upstream Processing01:27

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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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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...
Designing Growth Media for Bioreactors01:30

Designing Growth Media for Bioreactors

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...

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Decoding cultured meat manufacturing: a full process model to identify scale-up bottlenecks.

Katharina Julia Brenner1,2, Jan Harvey Lindermann1,2, Tjaša Sušnik1

  • 1Cellular Agriculture, TUM School of Life Sciences, Technical University of Munich, Freising, Germany.

Frontiers in Nutrition
|July 14, 2026
PubMed
Summary

A new process model for cultured meat production was developed to address scaling challenges. The model identifies key bottlenecks in media preparation, sterilization, and utility demand, guiding future industrialization efforts.

Keywords:
alternative proteinbioprocess optimizationcell-based foodcellular agriculturecultivated meatcultured meatmedia recyclingsustainable bioprocessing

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Published on: December 15, 2017

Area of Science:

  • Biotechnology
  • Chemical Engineering
  • Food Science

Background:

  • Scaling cultured meat production faces significant hurdles due to a lack of validated process models and engineering data.
  • Industrial translation of cellular agriculture is currently limited by insufficient understanding of large-scale manufacturing processes.

Purpose of the Study:

  • To develop a comprehensive process model for animal cell biomass production in suspension batch culture.
  • To integrate various unit operations, from media preparation to downstream processing, into a unified simulation framework.
  • To provide a reference for evaluating scalable cultivated biomass production concepts and identifying potential bottlenecks.

Main Methods:

  • Utilized SuperPro Designer v12 to model suspension-based cell proliferation for unstructured biomass production.
  • Integrated media preparation, cell expansion (up to 20,000 L), downstream clarification, washing, and extrusion into a single flowsheet.
  • Parameterized unit operations using literature data for mammalian suspension culture to establish mass and energy balances.

Main Results:

  • The model predicts approximately 2,000 kg of biomass per 30.7-day batch at a maximum cell density of 5x10^7 cells/mL.
  • Identified media preparation, sterilization, cleaning-in-place, and cooling as major scale-up bottlenecks.
  • Scale-out simulations indicated disproportionately high utility and cultivation time demands, highlighting waste and utility streams as critical for sustainability.

Conclusions:

  • The developed model serves as a reference framework, not a final design, for evaluating scalable cultivated biomass production.
  • It facilitates systematic assessment of process configurations, technical potential, and infrastructure needs before industrial implementation.
  • The model aids in preventing misdirected investments by enabling early-stage process evaluation for cellular agriculture.