Powered by Protein Production Technology International Scaling a fermentation process from a few liters in the lab to hundreds of cubic meters in commercial production is far more complex than simply making everything bigger. As volumes increase, challenges around oxygen transfer, heat removal, mixing, and energy consumption can determine whether a process remains productive and economically viable. In this episode of the Protein Production Technology International Podcast, Nick Bradley speaks with Annika Schmidt, Head of the Applications Group at EKATO, about the engineering considerations behind successful fermentation scale-up. The conversation explores why mass transfer is often one of the most important factors in scaling bioprocesses, and how oxygen transfer, agitation, heat transfer, and productivity are closely connected. Annika explains why optimizing one parameter in isolation can create problems elsewhere, and why the right approach must balance biological requirements with engineering realities. Annika also discusses why companies should consider scale-up early in process development. Investigating hydrodynamics, mixing times, power input, and heat transfer at smaller scales can help identify constraints before committing to expensive commercial equipment. The episode examines how scale-up studies and physical testing can inform decisions, reduce uncertainty, and help teams understand which process parameters must be preserved and which can be adapted. Beyond the biology and process performance, the discussion considers the practical demands of industrial equipment: mechanical stability, cleanability, maintenance, vessel design, and operating costs. Annika explains how these factors must be considered from the outset to create systems that are not only productive, but also robust and economical to operate. The episode also challenges common assumptions about fermentation scale-up, including the focus on impeller tip speed. Annika explains why specific power input can be a more useful consideration when assessing how agitation affects cells across different scales. For companies developing fermentation-based products, the key takeaway is clear: successful scale-up requires close collaboration between biology and engineering, careful investigation at each stage, and a production strategy designed with commercial realities in mind. The Future of Protein Production is connecting companies working to make the global protein system more sustainable, kind and fair for the planet, people, and animals. To find out more about our platform click here: https://www.futureofproteinproduction.com/ To read the most recent edition of Protein Production Technology, our multi-media magazine, click here: https://www.futureofproteinproduction.com/ #FutureOfProteinProduction #ProteinProductionTechnology #EKATO #Fermentation #ScaleUp #Bioprocessing #IndustrialBiotechnology #Biomanufacturing #Mixing #Agitation #MassTransfer #AlternativeProteins #FoodTech #FoodInnovation
