Project Overview
A U.S.-based biotechnology company specializing in algae-based products for food, nutrition, and sustainable materials approached Bailun to support their scale-up process.
As their research progressed, they encountered a key challenge:
How to efficiently transition from lab-scale R&D to pilot-scale production while maintaining process stability and product consistency.
The Challenge
The client needed to:
Scale from laboratory research to pilot production
Maintain consistent cultivation conditions across different volumes
Ensure reproducibility of biological performance
Minimize risks during scale-up
Establish a scalable platform for future industrial production
Algae cultivation presents unique technical challenges, especially in gas transfer, mixing, and process control, making scale-up particularly complex.
Our Solution
Bailun delivered a customized bioreactor solution, including:
Lab-Scale Development System
Multiple 15L bioreactors for strain development and process optimization
Accurate control of temperature, pH, dissolved oxygen (DO), and gas flow
Flexible configuration tailored for algae cultivation
Pilot-Scale Expansion System
150L bioreactors designed for seamless scale-up
Consistent design and control logic across scales
Reliable process transfer from lab to pilot
System Integration Advantages
Smooth transition from R&D to pilot scale
Unified control system across all units
Modular design enabling future expansion
Implementation Highlights
Fast installation and system commissioning
User-friendly control interface
Stable and reliable operation
Ongoing technical support during scale-up
Results & Impact
With Bailun’s support, the client successfully:
Achieved stable scale-up from 15L to 150L
Improved process consistency and reproducibility
Reduced development time from lab to pilot stage
Built a solid foundation for industrial-scale production
This enabled faster commercialization of algae-based products.
Why This Matters for Algae Production
Algae processes are highly sensitive to:
CO₂ transfer efficiency
Mixing and shear conditions
Nutrient and light distribution
A properly designed bioreactor system ensures:
Stable cultivation performance
Higher biomass yield
Scalable and repeatable processes
Looking to Scale Your Bioprocess?
Bailun provides complete solutions for:
Lab to pilot scale (5L – 50000L)
Custom bioreactor systems
Scalable process design
Full technical support