Executive Summary

Building on numerous successful pilot runs at their Alameda, California facility, Pow.Bio partnered with ATV Technologies in Compiègne, France to further scale Pow.Bio’s proprietary ML-enabled continuous platform to 3,000 L.

The overseas deployment demonstrated that Pow.Bio’s platform can be easily integrated within  external sites, such as contract manufacturing organizations (CMOs), unlocking cost effective biomanufacturing at ever-increasing scales.

The project achieved a seamless tech transfer and rapid deployment - tripling productivity and  establishing a new standard for bioprocess productivity and unit economics, while incorporating model predictive control for rapid success and process iteration in a manufacturing setting.

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Project Background 

Pow.Bio has demonstrated substantial cost advantages by converting fed-batch processes to its two-chamber continuous system across multiple hosts and product classes at the 2–300 L scale. To build client and industry confidence, external validation of this cost competitiveness at larger scales was essential. Pow.Bio therefore pursued a simultaneous tech transfer to a new operational environment while scaling the process to 10x the previous volume.

The target process - production of a high-value dairy protein - was uneconomical at expected manufacturing volumes using conventional fed-batch methods, making it an ideal candidate for continuous fermentation. Pow.Bio had already established a robust 2 L continuous process and successfully scaled it in-house to 300 L, demonstrating strong technical feasibility.

Yet scaling a complex bioprocess always introduces a mix of predictable and unforeseen challenges - risks that multiply when transferring operations to an external contract manufacturer. Against this backdrop, Pow.Bio set out to match or exceed its 300 L performance at significantly larger scale, in a new facility, and under an aggressive timeline.

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Objectives

The project aimed to:

• Demonstrate robust technology transfer to a new CMO environment
• Enable a CapEx-light adaptation of an existing manufacturing facility
• Replicate a 3x productivity improvement at larger scales
• Validate the scalability of Pow’s platform at 3,000 L and establish a pathway to 10,000 L
• Complete tech transfer and scale-up rapidly - within 10 weeks
  
  

The project also demonstrated that ML-powered predictive modeling could enable rapid site conversion and troubleshoot common scale-up challenges. 

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Execution Timeline

The timeline was ambitious: Pow. Bio set a goal for tech transfer, facility adaptation, and production within a single quarter. ATV and Pow.Bio worked closely to ensure seamless equipment integration and process readiness, moving from initial site assessment to 3,000 L continuous operation in under 10 weeks.

Facility Integration

Pow.Bio and ATV prioritized a pragmatic facility adaptation strategy to minimize the CapEx typically required for site conversions. Through targeted equipment modifications and the re-use of existing infrastructure (e.g., bioreactors, pumps, and filtration devices), the teams converted the facility without major additional equipment purchases or downtime.

Key modifications:

• Installed cell recycling system - Tangential Flow Filtration (TFF) skid 
• Adjusted media composition for continuous operation
• Re-purposed existing tanks for seed, feed, and harvest

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Result: With minimal CapEx, Pow.Bio delivered 3x more material, immediately expanding onsite functional capacity.

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Software Deployment: Cassie in Action

Cassie, Pow.Bio’s model-predictive controller, generated a digital model to guide the tech transfer and scale-up process tailored to the site requirements. The software’s simulation workflow ingested process updates, evaluated different scenarios, and identified optimal settings for the 3,000 L system. This confirmed Cassie’s role as a scalable digital twin and real-time optimization engine for biomanufacturing.

More specifically, the software was deployed to:

• Generate a prediction for how key parameters track throughout the process
• Test various hypotheses related to the unique system design, to achieve the best possible run configuration 
• Re-optimize parameters, in real-time, including feed rate setpoints
• Oversee the inoculation and production run for over 300 hours
• Solve for process deviations in real time
  
• E.g. Cassie dynamically adjusted permeation rates to compensate for higher than anticipated evaporation rates.

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Software Performance Data 

Key Results

The successful scale-up at ATV’s facility marked a critical milestone for Pow.Bio’s continuous fermentation technology. Across 300 hours of production, Pow.Bio’s system delivered exceptional reproducibility and adaptability, meeting or exceeding all predefined technical and economic targets. The project provided robust, third-party validation of the platform’s capacity to enhance productivity while substantially lowering both capital and operating costs.

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Highlights:

• ML-driven optimization automatically handled live process deviations
• Continuous operation achieved consistent yields and reproducibly higher productivity
• Minimal new hardware and rapid installation confirmed transferability

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Testimonial

"Working with Pow.Bio challenged us to rethink what’s possible in the fermentation process. By combining continuous processing with intelligent ML optimization, we achieved results that far exceeded our expectations. We’re proud to help prove this technology’s potential to scale and reshape the industry."

^{-Karima Zitouni, General Manager at ATV Technologies}

Summary & Conclusion

The successful scale-up at ATV’s facility represents a transformative breakthrough for Pow.Bio’s continuous fermentation platform. Over an extended 300-hour production campaign, the technology consistently delivered high-value, industrially relevant protein with remarkable stability and reproducibility. This milestone showcases how Pow.Bio’s innovative software and system design translate directly into significant productivity gains and cost savings - validating it as a commercially viable and practical solution for next-generation biomanufacturing. The project sets a strong foundation for accelerating scale-up efforts, expanding commercial deployments, and redefining industry standards for efficiency and economic impact.

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Next Steps

Pow.Bio is now focused on scaling Cassie-enabled continuous bioprocessing across further projects and larger capacities - targeting 5-15m³ scale with additional partners. 

For ATV, this proof equips them to offer highly competitive, ML-optimized continuous fermentation to their clients, supporting more efficient, rapid product launches.

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Contact Pow.Bio at scale@pow.bio to learn how our continuous bioprocessing solutions can help you achieve higher productivity, lower costs, and scalable success.

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Acknowledgment

Pow.Bio would like to acknowledge Bühler Group for their collaboration and support on this project. Bühler’s technical expertise, equipment integration, and shared commitment to advancing sustainable biomanufacturing were instrumental in achieving the outcomes described in this case study. Their partnership exemplifies how cross-industry collaboration can accelerate innovation and scale within the precision fermentation ecosystem.