From alternative proteins and fermentation-derived ingredients to the conversion of organic waste streams into valuable resources, advances in industrial biotechnology are opening new possibilities for producing food, feed, fuels and functional ingredients.
For many companies, however, the transition from the laboratory bench to a reliable production process remains a significant technical step. Early discoveries often begin in small-scale experimental systems, but translating these results into scalable, market-ready processes requires further development under conditions that more closely resemble industrial production. This is where pilot-scale research and development facilities play an important role.
Fermentation and microbial biotechnology are attracting increasing attention across several innovation areas. In the agrifood and food technology sectors, fermentation is being used to produce new types of proteins, lipids and functional ingredients. These technologies are helping companies explore more sustainable approaches to meeting global demand for protein while also enabling the development of new flavours, textures and nutritional profiles.
Beyond food, microbial processes are also being applied in areas such as enzyme production, biomaterials, speciality chemicals and renewable fuels.
Microorganisms can be used to produce complex molecules that would otherwise be difficult or resource-intensive to manufacture using conventional chemical routes.
Alongside this, there is growing interest in circular bioeconomy approaches, where biological processes are used to convert agricultural residues, food processing by-products and other organic materials into useful products or energy sources.
At AberInnovation, this broader industry trend is reflected in the increasing number of enquiries and projects focused on fermentation scale-up and microbial process development.
As processes are scaled up, several factors can influence performance, including:
For R&D teams, working in biotechnology or food technology, access to pilot-scale bioprocessing equipment allows these variables to be explored in a more realistic setting. Pilot-scale trials can help refine operating conditions, identify potential bottlenecks and generate data needed for further investment or industrial deployment.
Pilot-scale facilities typically bring together a range of technologies that support both upstream fermentation and downstream processing:
Bioreactors form the core of many microbial production processes. Pilot-scale bioreactors and fermenters enable researchers and companies to investigate how microorganisms behave under different conditions, including variations in temperature, aeration, agitation and nutrient supply.
These systems are commonly used in the development of processes for alternative proteins, microbial biomass production, fermentation-derived ingredients and industrial biotechnology applications.
Homogenisation technologies are often used during processing stages where cells need to be disrupted or where consistent particle size and product texture are important. In fermentation-based production, homogenisation can support cell disruption, ingredient formulation and the development of stable emulsions, particularly in food and ingredient applications.
Centrifugation plays an important role in solid–liquid separation, enabling the recovery of microbial biomass or the clarification of fermentation broths prior to further processing. Efficient separation is often a critical step when moving from laboratory research towards larger-scale production.
In addition to centrifugation, membrane filtration systems are often used to support the concentration and purification of fermentation broths, helping refine downstream processing steps during pilot-scale development.
For many emerging innovative organisations, establishing dedicated pilot-scale facilities can be expensive and time-consuming. Shared research environments can therefore provide an important route for companies to access specialised infrastructure while focusing their resources on technology development.
Facilities such as AberInnovation provide an environment where companies, researchers at IBERS – Aberystwyth University, and technical teams can explore new bioprocesses using pilot-scale fermentation, bioreactors and downstream processing equipment. This type of collaborative infrastructure can help organisations generate technical data, evaluate process performance and prepare technologies for further scale-up.
Biological innovation is expected to play an increasingly important role in the transition towards more sustainable production systems.
The ability to test, optimise and validate processes beyond the laboratory will remain a key step in bringing new technologies closer to commercial reality - companies can engage with our facilities in a number of ways, from collaborative research projects to contract R&D services, allowing technical teams to access specialised infrastructure, providing one pathway for innovators to explore how promising biological processes can evolve into practical solutions for food, feed, fuel and other bio-based products.