This document provides an overview of scaling up bioreactor production. It discusses the objectives of scaling up, which include producing product at a commercial scale to generate profit while lowering costs. The stages of scaling up studies are outlined, starting with screening studies, then progressing to laboratory, pilot, and industrial-scale fermenters. Key changes that occur during scale up include increased power needs, larger vessel sizes affecting temperature and pH control, and changes to sterilization and heat transfer processes. The conclusion emphasizes that the goal of scale up is to maximize efficient production at an industrial plant scale.

1. SCALE-UP OF BIOREACTOR
Prepared By Rahit Singha
BMLT, MSc. Microbiology
(Lynch, 2017)

2. INDEX
• Introduction
• Objective of scaling up
• When do we need scaling up studies
• Stages of scaling up studies
• Changes in operation of fermenters during scale up
• Conclusion
• References

3. INTRODUCTION
• Scale up in general is defined as increasing
something in size, amount, or production.
• The essence of scale-up of a fermentation
process is to demonstrate fermentation at large
scale resulting in the same productivity and
quality as that develop at small scale.
(Allman, 2021)

4. OBJECTIVE OF SCALING UP
• To produce product of commercial value and to derive profit from the process.
• To increase the production capacity of a unit, thus lowers both investment costs and the variable costs.
• To lower or reduce the production cost.
Scaling up production of Single Cell Protein from Spirulina Sp.

5. WHEN DO WE NEED SCALING UP STUDIES
• There is the need to do scaling ups in situation where we lack the
basic operating data for the fermentation process.
• This occurs in the situation such as:
1. New fermentation process
2. Change in medium/strains of bacteria/fungi used
3. New fermenters

6. STAGES OF SCALING UP STUDIES
1. Primary screening: solid media studies
2. Secondary screening (50ml – 1000ml)
3. Laboratory scale fermenters (5L – 20L)
4. Pilot scale fermenter (50L – 5000L)
5. Industrial scale fermenter (>5000L)
Industrial Scale (Marques MPC, 2017)

7. STAGES OF SCALING UP STUDIES
Primary Screening
Secondary Screening
Lab Scale Fermenter
Pilot Scale Fermenter
Industrial Fermenter
(Allman, 2021)

8. CHANGES IN THE OPERATION OF FERMENTERS
DURING SCALE UP
1. Power
 Bigger reactor needs more power
1. Size and Volume of fermenter
 Changes in size and volume will affect Temperature & pH control system
1. Heat Transfer
 Changes in size and complexity of huge fermenter vessel will affect sterilization process,
heat removal process

9. CONCLUSION
• Scale-up is the process of expanding a fermentation process from a
smaller-scale fermenter, where operational and production parameters
have been studied, to a larger scale. However, engineers’ ultimate goal is
to maximize production and efficiency in plant-scale production.

10. REFERENCES
• Marques MPC, Cabral JMS and Fernandes P. Bioprocess scale-up: quest for the parameters to be used as
criterion to move from microreactors to lab-scale. Journal of Chemical Technology and Biotechnology 2010;
85(9): 1184-1198
• Xia J, Wang G, Lin J, Wang Y, Chu J, Zhuang Y and Zhang S. Advances and Practices of Bioprocess Scale-up.
Adv Biochem Eng Biotechnol 2016; 152:137-51
• Hsu YL, Wu WT. A novel approach for scaling-up a fermentation system. Biochem Eng J. 2002;11:123–30.
• Islam RS, Tisi D, Levy MS, Lye GJ. Scale-up of Escherichia coli growth and recombinant protein expression
conditions from microwell to laboratory and pilot scale based on matched kLa. Biotechnol Bioeng.
2008;99(5):1128–39.
• Tang YJ, Zhang W, Liu RS, Zhu LW, Zhong JJ. Scale-up study on the fed-batch fermentation of Ganoderma
lucidum for the hyperproduction of ganoderic acid and Ganoderma polysaccharides. Process Biochem.
2011;46:404–8.

11. THANK YOU