Pilot Plants
(CDO Services)
ADL Pilot Plants: Scaling up your innovation to the next level
ADL has a broad know-how in the process development and scaling of new sustainable biotechnologies for multiple markets and industry sectors aimed at providing well-being to society (Food, Flavours and Fragrances, Functional Molecules, Personal Care and others).
Our Pilot Plants for Fermentation (USP) and Recovery and Purification (DSP) have been specifically designed to enable the transition from lab to industrial scale, through fully tailored services and an extensive knowledge on bioprocess innovation.
Our customers will find in ADL the preferred partner that will lead them through an efficient operational process to take their biotechnology procedure from the lab to the commercial scale, in a feasible, sustainable way. For this purpose, ADL has a fermentation scale-up capacity from lab up to 2,000 L along with a fully dedicated DSP facility.
ADL Pilot Plants for USP and DSP are open-access facilities
What does it mean?
They are open to the development of projects, from the starting stages to the tailor-made production to any start-up, small and medium enterprise (SME), large enterprise or research organization.
We make available to customers ready to use and state-of-the-art large-scale infrastructure, as well as the associated expertise that guarantees a fast and effective scaling-up.
All this enables the translation of laboratory scale innovations into industrially viable processes.
The Project outline is designed to achieve the highest profit.
Benefits of the open-access model:
- Saving time and money during the scaling-up process.
- Shortening the time required for a new product or process to reach the market.
- Lowering the financial risks associated with scale-up.
This is done on a contractual basis. There is a commitment to keep a very close communication throughout the development of the project, thus ensuring an effective transfer of technology.
FERMENTATION PILOT PLANT (USP)
This facility was completely refurbished in 2018 and has a total surface of about 1,000 m2.
Here, we optimize, scale-up and transfer the fermentation protocol from our customers from the lab up to 2,000 L. At this site we have four main functional areas: media preparation, semi pilot laboratory, pilot plant and control room.
What we offer:
- Process development and optimization.
- Scale up of fermentation processes.
- Withdrawal Batch and fed-batch aerobic fermentations.
- Experience with bacteria, yeasts, fungi, and microalgae.
- Authorized to work with BSL-1 & GMMs.
Main equipment:
Fermenters:
- 4 x 5 L
- 1 x 10 L
- 3 x 30 L
- 2 x 65 L
- 2 x 100 L
- 2 x 500 L
- 5 x 1,000 L
- 1 x 2,000 L
- Measuring/control technology for antifoam, speed, temperature, headspace pressure, pH value and dissolved oxygen concentration.
Auxiliary equipment:
- 10 feed vessels (140 – 250 – 500 L)
- 6 storage vessels (500 – 2,000 L)
RECOVERY AND PURIFICATION (DSP) PILOT PLANT
In this plant, the main DSP processes used in the industry including, but not limited, to extraction, purification, and isolation, are available to be conducted after the fermentation process. Our equipment and our team of highly qualified engineers and technicians along with our know-how and decades of experience allowed us to develop and launch of wide variety of projects, involving multi-step and complex technology.
What we offer:
- ATEX compliant installation.
- DSP processes (separation, extraction, and purification).
- Chemical synthesis / conversion processes.
- Process development and optimization.
Main equipment:
Reactors:
- 3 x 500 L
- 1 x 1,000 L
- 1 x 2,000 L
- 4 x 3,000 L
- 2 x 6,000 L
Glass lined reactors:
- 1 x 40 L
- 1 x 150 L
- 1 x 1,000 L
Utilities:
- Steam.
- Demineralized/process water.
- Brine (-15 °C to 70 °C).
- Vacuum (high/low).
- Nitrogen (gas/liquid).
- Compressed air.
Auxiliary equipment:
- Disk stack centrifuge (max. 350 L/h).
- Cross flow membrane filtration (MF, UF, NF).
- Rotatory filter.
- Batch evaporation reactors.
- Basket centrifuge (crystal separation).
- Drying oven.
- Rotatory vacuum dryer and filter dryer (100 L).
- Spray dryer mobile (0.5 – 5 kg/h water evaporation).
- High pressure homogenizer, cell disruptor (5 L/h).
- Rotatory evaporators.
- Ball / Hammer mills.
- Compactor.
Analytics
- UV/VIS spectrophotometer.
- Biochemical analyzer (YSI).
- HPLC equipment (DAD and RID).
- Gas Chromatography equipment (GC-FID).
- Protein analysis.
As part of our analytical services, ADL has fully equipped Quality Control laboratories for all kind of GMP compliance analyses (physico-chemical and microbiological).
Quality standards
Full monitoring of the processes (traceability, SOPs, etc.)
Authorized to work with BSL-1 & GMMs.
Experience in managing food grade, Halal and Kosher specifications.
