Scaling up bioreactors for a strong bioeconomy

Bioreactors – and the biological technologies they run on – have the potential to spur new bioindustrial manufacturing and expand the U.S. bioeconomy. But the key to that future is transferring bioreactor science and engineering to industry-scale.

Three Cyclone Engineering teams are working to bridge the gap between the lab and the large-scale use of bioreactors to manufacture bio-based products.

Fermentation Framework

“Scale-down” – studying and perfecting existing manufacturing-scale fermentation techniques at the small-scale – will guide the team in creating a new fermenter design and scale up framework that helps ensure lab discoveries can be scaled to industry processes.

Researchers: Rodney Fox, Anson Marston Distinguished Professor of Engineering; Dennis Vigil, Reginald R. Baxter Endowed Department Chair in Chemical and Biological Engineering; Zengyi Shao, Hershel B. Whitney Professor, Global Initiatives in Chemical and Biological Engineering; Ted Heindel, Bergles Professor in Thermal Science and University Professor of mechanical engineering, and Alberto Passalacqua, associate professor of mechanical engineering.

Project Partners: Cargill, Geno

Continuous Bioreactor

The team is creating a new type of continuous bioreactor that integrates product extraction and separation into the design, so less equipment is needed to complete the process.

Researchers: Dennis Vigil, Reginald R. Baxter Endowed Department Chair in Chemical and Biological Engineering, and Zengyi Shao, Hershel B. Whitney Professor, Global Initiatives in Chemical and Biological Engineering

Bioreactor Monitoring

Focused on enzyme production, the team is developing new product sensors that measure enzyme activity continuously and directly in the bioreactor, as well as the development of open-source monitoring software.

Researcher: Nigel Reuel, The Stanley Chair in Interdisciplinary Engineering

Project Partner: Novozymes

Proud Member of BioMADE: Iowa State University is a member of BioMADE, an independent, non-profit, public-private partnership catalyzed by the U.S. Department of Defense. By propelling new biotechnology products from the lab to the commercial market, BioMADE and its members strengthen American competitiveness, create a more robust and resilient supply chain, and help the U.S. become more self-sufficient.