Improving Biomass Throughput Using Automation

Did you know that with technologies like 96-deep-well plates, biotech labs can now run high-throughput experiments, sometimes handling up to 60 plates in parallel for massive screens? In a recent episode of the Smart Biotech Scientist Podcast, Tom Valentin, Group Leader at CSEM, shared that this setup can mean managing 5,760 individual samples at once (since each plate has 96 wells). That’s a game changer for process development: it speeds up optimization, enables robust data collection, and brings true automation to early-stage perfusion and fed-batch studies. For anyone in CMC or bioprocessing, this scale of miniaturization is opening doors to new efficiencies and more predictive results than ever before. Tom is pioneer in automated sample handling and miniaturized perfusion systems. With a unique blend of biomedical and mechanical engineering expertise, Tom is helping redefine what’s possible for small‑scale cell‑culture automation. Top 3 takeaways from our conversation: 1. Automation meets miniaturization: 96-deep-well plates offer high-throughput, low-volume experimentation that integrates seamlessly with liquid handling robots - paving the way for fully automated workflows in both fed-batch and perfusion processes. 2. Current limitations: Despite advances, replicating true bioreactor conditions at this small scale is still hampered by challenges in sensor miniaturization, precise liquid handling, and especially real-time viable cell density monitoring. 3. Next-gen solutions on the horizon: Tom and his team are working toward customizable perfusion systems compatible with existing platforms and exploring advanced sensor integration for real-time analytics, bringing fully automated, scalable biotech process development ever closer. Curious about how these insights could accelerate your own cell culture pipeline? Check out the full podcast episode or drop your questions/thoughts in the comments below. #HighThroughputScreening, #SmallScalePerfusion, #CellCultureAutomation, #BioprocessDevelopment, #ContinuousPerfusion, #FedBatchProcess, #MiniaturizedPerfusionSystems, #BioreactorConditions, #ProcessMonitoring, #CMCDevelopment

A new study introduces a novel method offering a high-throughput small-scale approach in plate format, ideal for rapid optimization in early-phase development, particularly in R&D and academic settings. This quasi-perfusion technique, combined with automation, simplifies the collection of quantitative data across various perfusion rates and feeding strategies. The incorporation of automation, utilizing advanced systems like a sterile TECAN robotic platform and a centrifuge, boosts process efficiency. Through automated tasks such as media exchange, the method allows for more frequent adjustments, closely mimicking real perfusion conditions within the Micro-Well Plate (MWP) system. The MWP methodology emerges as a cost-effective screening solution for media and cell lines in initial development stages, proving most effective in a perfusion-oriented setup. With a strategic approach involving culture supplementation with feed B, sodium butyrate integration, and the use of perfusion base media, an impressive 8-fold increase in monoclonal antibody (mAb) titre was accomplished. This innovative method accelerates the optimization process, leading to significant enhancements in mAb production, underscoring its potential to improve early-phase development outcomes.

From Briquettes to Clean Biomass: How this manufacturing unit in Goa cut fuel cost by ₹8, 00,000 per month! A PU/PVC coated fabric manufacturing unit in Goa with a 30 Lakh Kcal/h thermic fluid heater was facing challenges with high fuel costs, manual operations, and ash management. They were consuming 400 Tons of briquettes per month, costing them ₹10/kg. Steamax Envirocare stepped in with a dual solution: 1. Automatic fuel feeding system to eliminate manual handling. 2. A shift from briquettes to Astillas. The result? Game-changing: 🔥Fuel consumption reduced by 26.25%, down to just 295 tons/month (against 400 tons). 💸Monthly fuel bills reduced by ₹8, 00,000 🍀 Ash generation minimized from 40 tons to 5 tons per month. The transformation isn't just about numbers- it's a testament to how investing in automation can drive efficiency and sustainability. With more than 80 such fuel feeding automation projects, we are working to shift industries from manual feeding to a safer, reliable, efficient & low cost autofuel feeding systems.

⚖️ Balancing GSE Limits & 80% GHG Reduction: The Biomethane Feedstock Challenge Maximizing biomethane yield isn't just about feeding the digester. For plant operators, it’s a daily tightrope walk between maximizing output, respecting the authorized production capacity limits set by the GSE, and hitting the strict 80% GHG emission reduction target required for sustainability certification. Here is the operational approach to optimize the biomass mix without compromising compliance or performance: * Dynamic Mass Balancing: Relying on static recipes is risky. The key is continuous monitoring of the Biochemical Methane Potential (BMP) of incoming batches. Adjusting the daily feed rate based on real-time BMP ensures the plant stays right at the threshold of the GSE-authorized thermal/electrical capacity, preventing both underperformance and regulatory breaches. * Strategic Feedstock Prioritization: To achieve the 80% GHG reduction mandated by RED II/III, the diet must pivot heavily toward agricultural by-products, livestock effluents, and sequential/cover crops. Replacing primary energy crops (like traditional maize silage) lowers the carbon footprint of the biomethane lifecycle and improves the sustainability audit outcomes. * Digital Traceability: Proving the origin and the exact mix to auditors requires flawless data management. Granular tracking of the supply chain—from field to digester—is no longer optional. 💻 Software Solutions for Field Operations: Managing this complexity on spreadsheets leads to compliance errors. I recommend shifting to dedicated Biogas ERPs and predictive software integrated directly with plant SCADA systems. Platforms like BIOGAS-Manager, N-Biogas, or implementing custom Microsoft Power BI dashboards linked to the plant's PLC, allow for: * Real-time simulation of the digester's biological response. * Automated calculation of the daily GHG emission profile based on standard RED II values. * Alert systems for potential over-capacity before the feedstock is even loaded. Data-driven operations are the only way to merge technical performance with economic and regulatory compliance in the energy transition. Sources: European Commission (RED II/RED III Directives for biofuel sustainability criteria); GSE (Gestore Servizi Energetici) Guidelines on Biomethane. #Biomethane #BiogasOperations #Sustainability #GSE #GHGReduction #EnergyTransition #Bioenergy #PlantManagement #MassBalance #TechEconomist