Biomanufacturing & Fermentation Technology

prasad ernala

Welcome to Biomanufacturing & Fermentation Technology, the podcast where microbes meet manufacturing and science turns into scalable reality. In each episode, we dive inside real bioprocesses. from lab-scale experiments to commercial fermenters. to unpack how products are actually made, fixed, and optimized in the real world. Expect candid conversations on fermentation failures and breakthroughs, scale-up war stories, regulatory realities, emerging technologies, and the decisions that separate a promising culture from a profitable process. Whether you are a scientist, engineer, entrepreneur, o

  1. Execution Discipline, PAT, and Robustness Across Scale (QbD Part-3)

    -2 Ч

    Execution Discipline, PAT, and Robustness Across Scale (QbD Part-3)

    This part outlines how to bridge the gap between theoretical bioprocess models and the practical realities of large-scale manufacturing. It emphasizes that high-quality data and experimental discipline are the foundation of reliable models, particularly when transitioning from small shake flasks to complex bioreactors. The author explains how Process Analytical Technology (PAT) and soft sensors provide the real-time visibility necessary to maintain process control and ensure product quality. Furthermore, the expert advocates for robustness testing to identify stable operating plateaus rather than fragile performance peaks. By embedding scale-up physics and mixing dynamics into early development, engineer scan create processes that remain resilient against physical gradients and oxygen limitations. Ultimately, the text argues that integrating mechanistic understanding with rigorous execution ensures that optimized laboratory conditions translate successfully to commercial production. #Execution Discipline, PAT, and Robustness Across Scale (QbD Part-3) #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    22 мин.
  2. Defining and Mapping the Process CPPs, DoE, and Design Space (QbD Part-2)

    -1 ДН.

    Defining and Mapping the Process CPPs, DoE, and Design Space (QbD Part-2)

    This part outlines a systematic framework for applying Quality by Design (QbD) principles to bioprocessing, specifically within fermentation. It describes how to transform biological hypotheses into quantitative process maps by identifying Critical Process Parameters (CPPs) through both mechanistic understanding and statistical modeling. The discussion emphasizes the use of Design of Experiments (DoE) to efficiently explore interactions between variableslike temperature, pH, and oxygen transfer. These methodologies help define a multivariate design space where product quality is consistently maintained.Ultimately, the source advocates for prioritizing robust operating windows over fragile optima to ensure process reliability during scale-up. This structured approach ensures that biomanufacturing stays within regulatory and scientificboundaries throughout a product's lifecycle.#Defining and Mapping the Process CPPs, DoE, and Design Space (QbD Part-2) #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    19 мин.
  3. Foundations of QbD in Living Systems (QbD Part-1)

    -2 ДН.

    Foundations of QbD in Living Systems (QbD Part-1)

    This part explores the application of Quality by Design (QbD) principles to microbial fermentation, moving away from traditional reactive testing toward a proactive, science-based development framework. It highlights how the inherent variability of living systems—driven by genetic drift, nonlinear metabolic shifts, and environmental interactions—requires a more sophisticated approach than simple one-factor-at-a-time experimentation. By utilizing ICH regulatory guidelines, manufacturers can link a product’s clinical intent to critical quality attributes and specific process parameters. The discussion emphasize using structuredrisk management tools, such as FMEA, to identify how upstream biological fluctuations propagate through themanufacturing lifecycle. Ultimately, the material frames QbD as a disciplined strategy for navigating biological complexity to ensure consistent product safety and efficacy. #Foundations of QbD in Living Systems (QbD Part-1)#Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    17 мин.
  4. BIOMANUFACTURING AND FERMENTATION TECHNOLOGY, The Bioprocess Pulse – (13–19 Feb 2026).

    -5 ДН.

    BIOMANUFACTURING AND FERMENTATION TECHNOLOGY, The Bioprocess Pulse – (13–19 Feb 2026).

    This week discussion summarizes a bioprocessing industry report highlighting significant technical and economic shiftsoccurring in early 2026. Researchers have successfully engineered yeast to overcome production barriers for industrial chemicals, while artificial intelligence is now being used to optimize genetic coding and streamline complex regulatory compliance. The report forecasts substantial market growth in hardware and infrastructure, driven by international investments and new government manufacturing initiatives in China. However, thesource also offers a critical reality check regarding the economic limitations of precision fermentation for low-value goods. Industry founders and engineers are encouraged to prioritize scalable technology and rigorous cost-benefit analyses to ensure long-term viability. Ultimately, these updates illustrate a transition toward data-driven biology and intensified manufacturing processes within the global bioeconomy. #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    21 мин.
  5. Mechanistic Modeling and Mitigation of Fouling in Fermentation TFF

    -6 ДН.

    Mechanistic Modeling and Mitigation of Fouling in Fermentation TFF

    Hermia’s models categorize TFF fouling into four mechanisms, guiding regime identification and critical flux determination. Effective CIP protocols use caustic/acid washes to recover permeability. Digital twins combine mechanistic cores with AI to predict flux decline. How to use the result to minimize fouling in production TFF • Set your operating flux below the measured critical flux (often with a safety factor) to avoid sustained resistance growth. • If you observe a TMP “jump” pattern above certain fluxes, treat that as entering a new fouling regime and back off; TMP-jump behavior above critical/threshold flux is discussed as a characteristic signature in constant‑flux fouling studies. • Re-measure critical flux when any major variable changes (broth solids/viscosity, temperature, membrane lot, crossflow/channel geometry), because critical flux is not a membrane constant; it is an operating‑condition-dependent boundary. #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    15 мин.
  6. Programming the Cell Factory: Aligning Cellular Decision-Making and Control

    18 ФЕВР.

    Programming the Cell Factory: Aligning Cellular Decision-Making and Control

    This episode outlines a shift in bioprocessing strategy from maintaining static setpoints to designing dynamic environmental trajectories that align with internal cellular decision-making. Rather than treating microbes as passive catalysts, the author argues that scientists should use benchtop bioreactors to program specific patterns of stress, growth rates, and nutrient feeds. By treating variables like dissolved oxygen dips and temperature shifts as intentional design tools, researchers can better predict how populations will behave at an industrial scale. This discussion focuses on managing phenotypic subpopulations and metabolic burdens to ensure cells prioritize product synthesis over repair. Ultimately, the source provides a framework for using timed perturbations and phased growth strategies to achieve higher yields and more reproducible fermentation outcomes. #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    22 мин.
  7. TFF Failure Mechanisms and Digital Twin Diagnostics

    17 ФЕВР.

    TFF Failure Mechanisms and Digital Twin Diagnostics

    This episode examines the technical challenges and failure mechanisms associated with using tangential flow filtration (TFF) for processing fermentation broths. It details how microfiltration (MF), ultrafiltration (UF), and diafiltration (DF) are impacted by dynamic fouling, ranging from initial pore blocking to irreversible cake compaction. The discussion emphasize that scaling these processes to an industrial level often introduces hydrodynamic inconsistencies and logistical complexities that are not present in laboratory settings. To address these issues, the text proposes the use of digital twins and AI frameworks to monitor hidden resistance states and identify regime shifts in real time. Ultimately, these advanced models allow for targeted mitigation strategies that improve membrane longevity and process efficiency during large-scale production. #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    19 мин.
  8. Tangential Flow Filtration: Industrial Principles and Fermentation Applications

    16 ФЕВР.

    Tangential Flow Filtration: Industrial Principles and Fermentation Applications

    This episode serves as a comprehensive guide to Tangential Flow Filtration (TFF) within the context of industrial fermentation, moving from foundational mechanics to advanced digital applications. It defines TFF as a pressure-driven separation process where fluid flows parallel to the membrane to mitigate, though not entirely prevent, the accumulation of debris and fouling. The discussion details the critical interplay between operating parameters like transmembrane pressure and crossflow velocity, emphasizing that improper balance can lead to irreversible membrane damage or cell lysis. Beyond basic hardware, the sources explore specific applications in microfiltration, ultrafiltration, and diafiltration for product clarification and concentration. Finally, the text highlights the shift toward digital-twin technology and AI to predict fouling regimes and optimize processing stability in complex biological environments. #Bioprocess #ScaleUp and #TechTransfer,#Industrial #Microbiology,#MetabolicEngineering and #SystemsBiology,#Bioprocessing,#MicrobialFermentation,#Bio-manufacturing,#Industrial #Biotechnology,#Fermentation Engineering,#ProcessDevelopment,#Microbiology,#Biochemistry,#Biochemical Engineering, #Applied #MicrobialPhysiology, #Microbial #ProcessEngineering, #Upstream #BioprocessDevelopment, #Downstream Processing and #Purification,#CellCulture and #MicrobialSystems Engineering, #Bioreaction #Enzymes, #Biocatalyst #scientific #Scientist #Research

    20 мин.
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Welcome to Biomanufacturing & Fermentation Technology, the podcast where microbes meet manufacturing and science turns into scalable reality. In each episode, we dive inside real bioprocesses. from lab-scale experiments to commercial fermenters. to unpack how products are actually made, fixed, and optimized in the real world. Expect candid conversations on fermentation failures and breakthroughs, scale-up war stories, regulatory realities, emerging technologies, and the decisions that separate a promising culture from a profitable process. Whether you are a scientist, engineer, entrepreneur, o

Информация

  • Автор
    prasad ernala
  • Годы выхода
    2 тыс.
  • Выпуски
    60
  • Ограничения
    Без ненормативной лексики
  • Авторские права
    © prasad ernala
  • Сайт подкаста
    Biomanufacturing & Fermentation Technology