Bioprocess development and scale-up

Bioprocess development

Optimising bioprocesses for efficiency, scalability, and commercial success.

Get in touch

View capabilities

From lab to industrial scale

Successful bioprocess development requires a deep understanding of fermentation, media formulation, and process optimisation. At CPI, we help accelerate your journey from proof-of-concept to commercial-scale production by providing the expertise, facilities, and innovation support needed to optimise and scale your bioprocess. 

Our approach integrates high-throughput experimentation, data-driven process optimisation, and advanced scale-down modelling to help you develop commercially viable, sustainable, and efficient bioprocesses.

Whether microbial, mammalian, or plant-based systems, our tailored solutions enable smooth scale-up, de-risking your development pathway and ensuring a seamless transition to industrial production. 

CPI expert at a fermentation facility.

Bioprocess development and scale-up

Bioprocess development

Optimising bioprocesses for efficiency, scalability, and commercial success.

Get in touch

View capabilities

From lab to industrial scale

Successful bioprocess development requires a deep understanding of fermentation, media formulation, and process optimisation. At CPI, we help accelerate your journey from proof-of-concept to commercial-scale production by providing the expertise, facilities, and innovation support needed to optimise and scale your bioprocess. 

Our approach integrates high-throughput experimentation, data-driven process optimisation, and advanced scale-down modelling to help you develop commercially viable, sustainable, and efficient bioprocesses.

Whether microbial, mammalian, or plant-based systems, our tailored solutions enable smooth scale-up, de-risking your development pathway and ensuring a seamless transition to industrial production. 

CPI expert at a fermentation facility.

Bioprocess development and scale-up

Bioprocess development

Optimising bioprocesses for efficiency, scalability, and commercial success.

Get in touch

View capabilities

From lab to industrial scale

Successful bioprocess development requires a deep understanding of fermentation, media formulation, and process optimisation. At CPI, we help accelerate your journey from proof-of-concept to commercial-scale production by providing the expertise, facilities, and innovation support needed to optimise and scale your bioprocess. 

Our approach integrates high-throughput experimentation, data-driven process optimisation, and advanced scale-down modelling to help you develop commercially viable, sustainable, and efficient bioprocesses.

Whether microbial, mammalian, or plant-based systems, our tailored solutions enable smooth scale-up, de-risking your development pathway and ensuring a seamless transition to industrial production. 

  • Oxford Biotrans
  • Calysta
  • Azotic
  • 3D Bio-Tissues
  • Newcastle University
  • Immune Boost Clinic

What we offer

We specialise in microbial fermentation and tailored bioprocessing solutions for both anaerobic and aerobic systems, supporting a wide range of species, including bacterial, fungal, yeast, algae, mammalian, and plant cells. From scale-down high-throughput studies (1mL to 10L) to larger-scale manufacturing (100L to 10,000L), we ensure efficient bioprocess development for successful scale-up and commercialisation within a single facility. We also support short- and long-term contract manufacturing campaigns.

What we offer

We specialise in microbial fermentation and tailored bioprocessing solutions for both anaerobic and aerobic systems, supporting a wide range of species, including bacterial, fungal, yeast, algae, mammalian, and plant cells. From scale-down high-throughput studies (1mL to 10L) to larger-scale manufacturing (100L to 10,000L), we ensure efficient bioprocess development for successful scale-up and commercialisation within a single facility. We also support short- and long-term contract manufacturing campaigns.

What we offer

We specialise in microbial fermentation and tailored bioprocessing solutions for both anaerobic and aerobic systems, supporting a wide range of species, including bacterial, fungal, yeast, algae, mammalian, and plant cells. From scale-down high-throughput studies (1mL to 10L) to larger-scale manufacturing (100L to 10,000L), we ensure efficient bioprocess development for successful scale-up and commercialisation within a single facility. We also support short- and long-term contract manufacturing campaigns.

High-throughput bioprocess optimisation

Our upstream development facilities support the creation of robust, scalable bioprocesses, enabling the production of food, feed, AgriTech, and sustainable materials for market testing. CPI’s dedicated scale-down facilities recreate large-scale industrial fermenters in the laboratory, allowing us to study key process variables such as pH, temperature, dissolved oxygen, shear forces, and nutrient gradients while avoiding the high costs of full-scale operations. 

  • High-throughput automated bioreactors (including BioLector and Ambr 250) enable rapid process development and scale-down studies. 

  • Parallel 1L systems provide high-quality data for robust process development. 

High-throughput bioprocess optimisation

Our upstream development facilities support the creation of robust, scalable bioprocesses, enabling the production of food, feed, AgriTech, and sustainable materials for market testing. CPI’s dedicated scale-down facilities recreate large-scale industrial fermenters in the laboratory, allowing us to study key process variables such as pH, temperature, dissolved oxygen, shear forces, and nutrient gradients while avoiding the high costs of full-scale operations. 

  • High-throughput automated bioreactors (including BioLector and Ambr 250) enable rapid process development and scale-down studies. 

  • Parallel 1L systems provide high-quality data for robust process development. 

Fermentation, cell culture, and molecular farming

Our expertise spans microbial, mammalian, and plant cell culture, allowing us to optimise fermentation conditions and downstream processes to improve reproducibility across multiple biological systems. 

  • Custom bioreactor configurations enhance productivity and process control. 

  • Nutrient delivery and media formulation strategies optimise metabolic activity. 

  • Expertise in sustainable feedstocks, including C1 gases (CO₂, CH₄) for microbial gas fermentations. 

  • Assessment of fermentation vessel configurations including stirred tank, tubular and bag fermenters to deliver the best solution for your product or process. 

  • Assessment of cultivation modes from batch to continuous to optimise process economics. 

Fermentation, cell culture, and molecular farming

Our expertise spans microbial, mammalian, and plant cell culture, allowing us to optimise fermentation conditions and downstream processes to improve reproducibility across multiple biological systems. 

  • Custom bioreactor configurations enhance productivity and process control. 

  • Nutrient delivery and media formulation strategies optimise metabolic activity. 

  • Expertise in sustainable feedstocks, including C1 gases (CO₂, CH₄) for microbial gas fermentations. 

  • Assessment of fermentation vessel configurations including stirred tank, tubular and bag fermenters to deliver the best solution for your product or process. 

  • Assessment of cultivation modes from batch to continuous to optimise process economics. 

Process scale-up and validation

CPI’s infrastructure ensures seamless progression from laboratory development to commercial-scale production, reducing risk and accelerating time to market. 

  • Our National Industrial Biotechnology Facility is an open-access site for pilot- and demonstration-scale fermentation, enabling scale-up to 750L, 2000L, and 10,000L.

  • Our Novel Food Innovation Centre supports process development, market sample production and scale-up through 50L, 100L, and 400L food-grade fermentation all within a single location. 

  • Scale-up modelling and computational simulations ensure efficient transition across production scales. 

  • Expertise in biomass fermentation, gas fermentation, and precision fermentation supports a diverse range of industries. 

  • Regulatory adherence (HACCP, FDA, and FSSC 22000) ensures compliance for sustainable food and feed applications. 

Process scale-up and validation

CPI’s infrastructure ensures seamless progression from laboratory development to commercial-scale production, reducing risk and accelerating time to market. 

  • Our National Industrial Biotechnology Facility is an open-access site for pilot- and demonstration-scale fermentation, enabling scale-up to 750L, 2000L, and 10,000L.

  • Our Novel Food Innovation Centre supports process development, market sample production and scale-up through 50L, 100L, and 400L food-grade fermentation all within a single location. 

  • Scale-up modelling and computational simulations ensure efficient transition across production scales. 

  • Expertise in biomass fermentation, gas fermentation, and precision fermentation supports a diverse range of industries. 

  • Regulatory adherence (HACCP, FDA, and FSSC 22000) ensures compliance for sustainable food and feed applications. 

Digitalisation and advanced modelling

We integrate digital tools and modelling techniques to enhance process predictability and efficiency, reducing costs and mitigating risks. 

  • Computational fluid dynamics (CFD) optimises bioreactor performance and flow dynamics to ensure process scalability.  

  • Process analytical technology (PAT) ensures real-time monitoring and control. 

  • Digital twin technology enables virtual simulations for scalability and optimisation. 

  • Machine learning-driven process analytics support continuous process improvement. 

Digitalisation and advanced modelling

We integrate digital tools and modelling techniques to enhance process predictability and efficiency, reducing costs and mitigating risks. 

  • Computational fluid dynamics (CFD) optimises bioreactor performance and flow dynamics to ensure process scalability.  

  • Process analytical technology (PAT) ensures real-time monitoring and control. 

  • Digital twin technology enables virtual simulations for scalability and optimisation. 

  • Machine learning-driven process analytics support continuous process improvement. 

Can’t find what you’re looking for?

With over 500 experts we are here to help.

Get in touch

Can’t find what you’re looking for?

With over 500 experts we are here to help.

Get in touch

Can’t find what you’re looking for?

With over 500 experts we are here to help.

Get in touch

Bioprocess development applications

We support various sectors in developing and optimising bioprocesses for commercial success.

Alternative proteins.

Functional ingredients.

Functional food and beverages.

Sustainable chemicals and materials.

Cosmetic and personal care ingredients.

Enzymes for biocatalytic processes.

Biopesticides, biostimulants and biofertilisers.

Nutraceuticals.

CPI scientist collecting an amber liquid sample into a bottle from stainless steel fermentation equipment.

Bioprocess development applications

We support various sectors in developing and optimising bioprocesses for commercial success.

Alternative proteins.

Functional ingredients.

Functional food and beverages.

Sustainable chemicals and materials.

Cosmetic and personal care ingredients.

Enzymes for biocatalytic processes.

Biopesticides, biostimulants and biofertilisers.

Nutraceuticals.

CPI scientist collecting an amber liquid sample into a bottle from stainless steel fermentation equipment.

Bioprocess development applications

We support various sectors in developing and optimising bioprocesses for commercial success.

Alternative proteins.

Functional ingredients.

Functional food and beverages.

Sustainable chemicals and materials.

Cosmetic and personal care ingredients.

Enzymes for biocatalytic processes.

Biopesticides, biostimulants and biofertilisers.

Nutraceuticals.

CPI scientist collecting an amber liquid sample into a bottle from stainless steel fermentation equipment.

How we support you

At CPI, we offer access to industry-relevant scale-up infrastructure and industry-experienced scientists and technologists, ensuring a smooth transition from early-stage development to commercial-scale manufacturing.

How we support you

At CPI, we offer access to industry-relevant scale-up infrastructure and industry-experienced scientists and technologists, ensuring a smooth transition from early-stage development to commercial-scale manufacturing.

How we support you

At CPI, we offer access to industry-relevant scale-up infrastructure and industry-experienced scientists and technologists, ensuring a smooth transition from early-stage development to commercial-scale manufacturing.

Optimise and de-risk your bioprocesses

We help you navigate the complexities of bioprocess development, optimising performance and reducing variability. Our expertise spans from proof-of-concept to industrial production, ensuring that your process is scalable and commercially viable. 

Optimise and de-risk your bioprocesses

We help you navigate the complexities of bioprocess development, optimising performance and reducing variability. Our expertise spans from proof-of-concept to industrial production, ensuring that your process is scalable and commercially viable. 

Scale with confidence

Moving from lab-scale to full-scale production can be complex. We provide access to pilot and demonstration-scale facilities, allowing you to validate and refine your bioprocess before commercial-scale investment. Our techno-economic analyses and process validation studies help de-risk scale-up, ensuring a smooth transition to market. We can also facilitate the transfer your process to third-party partners or support the design of your own bespoke reactor systems. 

Scale with confidence

Moving from lab-scale to full-scale production can be complex. We provide access to pilot and demonstration-scale facilities, allowing you to validate and refine your bioprocess before commercial-scale investment. Our techno-economic analyses and process validation studies help de-risk scale-up, ensuring a smooth transition to market. We can also facilitate the transfer your process to third-party partners or support the design of your own bespoke reactor systems. 

Intellectual property development and protection

We help you to develop and secure your own IP by providing an established environment for innovation. Our expert teams work closely with you to develop your proprietary processes and innovations, helping you maintain a competitive edge in the market. 

Intellectual property development and protection

We help you to develop and secure your own IP by providing an established environment for innovation. Our expert teams work closely with you to develop your proprietary processes and innovations, helping you maintain a competitive edge in the market. 

Navigate regulatory and commercial hurdles

We integrate digital tools and modelling techniques to enhance process predictability and efficiency, reducing costs and mitigating risks. 

  • Computational fluid dynamics (CFD) optimises bioreactor performance and flow dynamics to ensure process scalability.  

  • Process analytical technology (PAT) ensures real-time monitoring and control. 

  • Digital twin technology enables virtual simulations for scalability and optimisation. 

  • Machine learning-driven process analytics support continuous process improvement. 

Navigate regulatory and commercial hurdles

We integrate digital tools and modelling techniques to enhance process predictability and efficiency, reducing costs and mitigating risks. 

  • Computational fluid dynamics (CFD) optimises bioreactor performance and flow dynamics to ensure process scalability.  

  • Process analytical technology (PAT) ensures real-time monitoring and control. 

  • Digital twin technology enables virtual simulations for scalability and optimisation. 

  • Machine learning-driven process analytics support continuous process improvement. 

Facilitate investment and accelerate innovation

Access to funding is critical for scaling up innovations. We support you in securing public and private investment through grant applications, private funding rounds, and strategic partnerships that drive long-term growth. By collaborating with industry, academia, and government, we provide access to funding opportunities, expertise, and market insights to accelerate your innovation journey. Whether you need investment, market strategy refinement, or enhanced process efficiency, CPI is your trusted partner in bioprocess development. 

Facilitate investment and accelerate innovation

Access to funding is critical for scaling up innovations. We support you in securing public and private investment through grant applications, private funding rounds, and strategic partnerships that drive long-term growth. By collaborating with industry, academia, and government, we provide access to funding opportunities, expertise, and market insights to accelerate your innovation journey. Whether you need investment, market strategy refinement, or enhanced process efficiency, CPI is your trusted partner in bioprocess development. 

  • CPI scientist using a VWR pipette controller to fill a serological pipette in a laboratory.
    Gloved scientist using a pipette to fill blue microplates at a laboratory bench.
  • Automated sampler probe dipping into a sample tube in a rack, with a CPI scientist watching behind.
    CPI scientist operating an ambr 250 automated bioreactor system with a tablet.
  • Stainless steel pilot process rig with looped pipework and a blue pump in a facility.
  • CPI scientist working at a HEL parallel automated reactor system behind a glass door.
    CPI scientist drawing a process diagram on a glass screen in a laboratory.
  • Gloved hands holding a petri dish with a bacterial streak culture while using an inoculation tool.
    CPI scientist using an Olympus microscope with the magnified sample shown on a monitor.
  • Gloved hand holding a petri dish with orange bacterial colonies streaked across the agar.
  • CPI scientist using a VWR pipette controller to fill a serological pipette in a laboratory.
    Gloved scientist using a pipette to fill blue microplates at a laboratory bench.
  • Automated sampler probe dipping into a sample tube in a rack, with a CPI scientist watching behind.
    CPI scientist operating an ambr 250 automated bioreactor system with a tablet.
  • Stainless steel pilot process rig with looped pipework and a blue pump in a facility.
  • CPI scientist working at a HEL parallel automated reactor system behind a glass door.
    CPI scientist drawing a process diagram on a glass screen in a laboratory.
  • Gloved hands holding a petri dish with a bacterial streak culture while using an inoculation tool.
    CPI scientist using an Olympus microscope with the magnified sample shown on a monitor.
  • Gloved hand holding a petri dish with orange bacterial colonies streaked across the agar.
  • CPI scientist using a VWR pipette controller to fill a serological pipette in a laboratory.
    Gloved scientist using a pipette to fill blue microplates at a laboratory bench.
  • Automated sampler probe dipping into a sample tube in a rack, with a CPI scientist watching behind.
    CPI scientist operating an ambr 250 automated bioreactor system with a tablet.
  • Stainless steel pilot process rig with looped pipework and a blue pump in a facility.
  • CPI scientist working at a HEL parallel automated reactor system behind a glass door.
    CPI scientist drawing a process diagram on a glass screen in a laboratory.
  • Gloved hands holding a petri dish with a bacterial streak culture while using an inoculation tool.
    CPI scientist using an Olympus microscope with the magnified sample shown on a monitor.
  • Gloved hand holding a petri dish with orange bacterial colonies streaked across the agar.
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Trusted by leading organisations

Showing slide 1 of 1
Oxford Biotrans

Our project with CPI was the springboard for our technology commercialisation programme and subsequent market launch. The CPI team were knowledgeable, approachable and responsive and proved invaluable in rapidly overcoming the complex challenges that developing any new process requires.

A headshot of Jason King. .

Jason King

CEO

Touchlight Genetics

CPI has skillsets and equipment that are not readily available anywhere else. By using CPI’s skills, we have saved many months of process development.

Headshot of Dr Jill Makin, CTO

Dr Jill Makin

CTO

Calysta

We chose Teesside as a preferred location due to the commercial attractiveness, technical skills and research and development expertise in the area.

Headshot of Alan Shaw, CEO

Alan Shaw

CEO

Trusted by leading organisations

Showing slide 1 of 1
Oxford Biotrans

Our project with CPI was the springboard for our technology commercialisation programme and subsequent market launch. The CPI team were knowledgeable, approachable and responsive and proved invaluable in rapidly overcoming the complex challenges that developing any new process requires.

A headshot of Jason King. .

Jason King

CEO

Touchlight Genetics

CPI has skillsets and equipment that are not readily available anywhere else. By using CPI’s skills, we have saved many months of process development.

Headshot of Dr Jill Makin, CTO

Dr Jill Makin

CTO

Calysta

We chose Teesside as a preferred location due to the commercial attractiveness, technical skills and research and development expertise in the area.

Headshot of Alan Shaw, CEO

Alan Shaw

CEO

Trusted by leading organisations

Showing slide 1 of 1
Oxford Biotrans

Our project with CPI was the springboard for our technology commercialisation programme and subsequent market launch. The CPI team were knowledgeable, approachable and responsive and proved invaluable in rapidly overcoming the complex challenges that developing any new process requires.

A headshot of Jason King. .

Jason King

CEO

Touchlight Genetics

CPI has skillsets and equipment that are not readily available anywhere else. By using CPI’s skills, we have saved many months of process development.

Headshot of Dr Jill Makin, CTO

Dr Jill Makin

CTO

Calysta

We chose Teesside as a preferred location due to the commercial attractiveness, technical skills and research and development expertise in the area.

Headshot of Alan Shaw, CEO

Alan Shaw

CEO

Why choose CPI?

Work with us to defer capital and workforce investments until your product or process is proven at scale.

High-throughput capability

Accelerated bioprocess development using state-of-the-art automated systems.

End-to-end scale-up

Pilot to commercial-scale facilities supporting confident process transitions.

Precision optimisation

Tailored process solutions for microbial, plant, and mammalian cell systems.

Comprehensive infrastructure

Food-grade facilities ensuring compliance and quality for commercial products.

Experienced scientists

Dedicated bioprocess experts with extensive industrial experience.

Robust IP and regulatory guidance

Comprehensive support to protect innovations and streamline regulatory pathways.

Why choose CPI?

Work with us to defer capital and workforce investments until your product or process is proven at scale.

High-throughput capability

Accelerated bioprocess development using state-of-the-art automated systems.

End-to-end scale-up

Pilot to commercial-scale facilities supporting confident process transitions.

Precision optimisation

Tailored process solutions for microbial, plant, and mammalian cell systems.

Comprehensive infrastructure

Food-grade facilities ensuring compliance and quality for commercial products.

Experienced scientists

Dedicated bioprocess experts with extensive industrial experience.

Robust IP and regulatory guidance

Comprehensive support to protect innovations and streamline regulatory pathways.

Why choose CPI?

Work with us to defer capital and workforce investments until your product or process is proven at scale.

High-throughput capability

Accelerated bioprocess development using state-of-the-art automated systems.

End-to-end scale-up

Pilot to commercial-scale facilities supporting confident process transitions.

Precision optimisation

Tailored process solutions for microbial, plant, and mammalian cell systems.

Comprehensive infrastructure

Food-grade facilities ensuring compliance and quality for commercial products.

Experienced scientists

Dedicated bioprocess experts with extensive industrial experience.

Robust IP and regulatory guidance

Comprehensive support to protect innovations and streamline regulatory pathways.

Get in touch

Get in touch

Get in touch

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