FOOD
& INGREDIENTS
Boccard is currently developing a modular biotechnology installation as part of its TEKINBIO™ offering for an Eastern European client, designed to support fermentation from pilot-scale work to larger production volumes. The project brings together three bioreactors with working capacities of 50, 500 and 5,000 litres, a 2,500-litre media preparation tank, transfer systems and the process infrastructure required to operate the bioreactors independently or in cascade mode.
Discover how Boccard is supporting an Eastern European biotechnology client in developing a flexible and scalable fermentation installation, designed to connect research, process development and larger-scale production.
From process development to increased fermentation capacity
The three TEKINBIO™ bioreactor scales are intended to provide continuity between early process work and larger production batches. Each vessel can be operated independently, while cascade operation is designed to support the transfer of material between successive scales.
This configuration gives the future user several operating options: developing processes at different volumes, preparing inoculum for a larger vessel and running separate fermentation activities according to research or production needs.
The installation is also being designed to accommodate processes with different operating profiles, from shorter batch cycles to extended fermentation campaigns. The objective is to provide a common platform that can adapt to evolving biotechnology applications without requiring a separate installation for every scale.
Figure 1. 3D render of the multi-bioreactor fermentation installation, from 50 to 5,000 L
Integrated process control and automation
Automation is a central workstream in the project. The control architecture is being developed to coordinate the three bioreactors, media preparation, transfers, dosing, temperature control, gas management, cleaning operations and process analytics.
Each bioreactor is designed with instrumentation for pH, dissolved oxygen, temperature and biomass monitoring, together with gas filtration and a dedicated temperature control unit. The analytical scope also includes CO₂, O₂ and ethanol measurement, supported by dedicated dosing systems for process additives.
The project teams are refining the functional requirements with the client throughout execution, ensuring that operating sequences, interfaces, alarms and process functions remain aligned with the intended use of the installation.
A modular installation engineered for the available space
The installation is being developed around modular process skids and extensive prefabrication in Poland. Advanced 3D design supports the positioning of vessels, piping, valves and access areas before delivery to the customer’s site in Eastern Europe.
This approach is intended to limit on-site assembly, improve installation sequencing and support controlled commissioning. The design also considers hygienic operation, drainability, cleanability and access for operation and maintenance within the available footprint.
Figure 2. View of installation composed of modular and prefabricated process skids
Figure 3. View of installation piping and valves connecting various modules
Utilities and resource efficiency considered from the design stage
Resource efficiency is being addressed during engineering rather than after installation. The current design includes provisions for recovering condensate for process-steam generation and for reusing selected cleaning utilities in other parts of the installation after appropriate decontamination.
Equipment and valve selection is based on the actual process parameters and utility requirements. This engineering work aims to balance process performance, hygienic design, energy use and reliable operation across the different bioreactor scales.
A collaborative biotechnology project led by Boccard
The project mobilises process technologists, mechanical and 3D designers, automation specialists, production and installation teams, purchasing specialists and expertise from across Boccard.
By combining multiple fermentation scales, process automation, hygienic engineering and modular fabrication, Boccard is supporting the client in developing a versatile TEKINBIO™ fermentation platform for future biotechnology activities.
The project also strengthens Boccard’s capacity to deliver integrated fermentation installations that connect process development with larger-scale production. Further information can be shared once the project reaches the appropriate stage and communication has been agreed with the client.
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Key points
Independent and cascade operating modes, with product transfer between successive bioreactors.
pH, dissolved oxygen, temperature and biomass monitoring, complemented by CO₂, O₂ and ethanol analysis.
Integrated process automation, coordinating media preparation, transfers, dosing and cleaning, including a CIP station with cleaning loop.
scope of work, EQUIPMENT AND SERVICES SUPPLIED
- Engineering & skid prefabrication: Process engineering, 3D design and modular skid development, with extensive prefabrication in Poland and equipment layout adapted to the available space.
- Fermentation equipment: 3 TEKINBIO™ bioreactors of 50, 500 and 5,000 L, a 2,500 L media preparation tank and product-transfer systems for independent or cascade operation.
- Instrumentation & automation: Integrated control of fermentation, media preparation, transfers and dosing, with dedicated temperature-control units, process sensors and CO₂, O₂ and ethanol analysers.
- Cleaning equipment: CIP station with cleaning loop, integrated into an installation designed for hygienic operation, drainability and cleanability.
- Utilities integration: Provisions for condensate recovery for process-steam generation and reuse of selected cleaning utilities after appropriate decontamination.
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