Pow.Bio, Bühler, and ATV Technologies Announce Major Advancement in Continuous Biomanufacturing with 3,000-Liter Scale Success

Pow.Bio, a leader in continuous biomanufacturing, Bühler Group, a global provider of food, feed, and ingredient processing solutions, and ATV Technologies, an innovator in fermentation process industrialization, have successfully scaled Pow.Bio’s continuous platform to 3,000 liters at ATV's facility in Compiègne, France. This achievement produces three times more protein than traditional fed-batch processes and marks a significant milestone in validating Pow.Bio’s technology at larger scales.

The project not only enhances productivity but also drastically reduces the cost of goods sold (COGS). Pow.Bio's advanced machine learning (ML) algorithms and model predictive control systems have replaced traditional methods with data-driven decision-making, allowing for real-time adjustments to operational challenges.

ATV's expertise has been instrumental in reaching this critical proof point, showcasing that continuous fermentation can be effectively integrated at larger scales with robust, globally scalable performance. Key outcomes from this collaboration include:

- Higher Productivity: Pow.Bio’s platform has increased productivity for high-quality dairy protein by more than threefold compared to fed-batch methods.
- Reduced COGS: The new process has cut projected costs of goods sold by over 50% compared to traditional methods.
- Nimble Conversion: Pow.Bio’s adaptation of ATV’s existing facility has generated three times more product from minimal investment, with Bühler providing essential expertise for adapting the site for continuous trials.
- ML-Driven Process Adaptability: Advanced machine learning and predictive control have rapidly enhanced process outcomes through novel optimization strategies tailored to facility-specific needs.

Prior to the trials, Bühler conducted a thorough pre-qualification of ATV’s site, ensuring readiness for continuous fermentation and aligning the facility with operational requirements. They also facilitated the adaptation of existing infrastructure for continuous operations and supported a smooth technology transfer from Pow.Bio to ATV, expediting trial initiation and execution.

"ATV has been a reliable partner with a highly skilled team who have helped bring our technology to life at a larger scale. This collaboration proves that our continuous fermentation platform delivers reliably at scales that matter with unmatched economic viability," remarked Shannon Hall, CEO and co-founder of Pow.Bio. "What excites me the most is that our customers can now leverage our technology to get to market faster than ever before. As we advance toward even larger scales, this is one of many partnerships that validate our approach to transforming global biomanufacturing."

"Working with Pow.Bio challenged us to rethink what's possible in fermentation," stated Karima Zitouni, General Manager at ATV Technologies. "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."

"We've demonstrated that today's biomanufacturing lines can be made truly data-driven and self-optimizing - delivering higher yields, greater stability, and consistent performance at scale - by implementing predictive, continuous fermentation at ATV, using Pow.Bio’s technology. Importantly, the method can be quickly implemented throughout the current infrastructure by being retrofitted into existing plants," said Thierry Duvanel, Director of Innovation at Bühler Group. "This is a significant step toward dependable continuous operation at larger scales, particularly in the demanding markets of food, feed, and ingredient biomanufacturing."

The success achieved with ATV is a crucial milestone in the journey toward industrial scales of continuous biomanufacturing. This collaboration illustrates that Pow.Bio’s advanced technology, combined with ML-driven process control, can be seamlessly integrated at CMO facilities to enhance economics at unprecedented speed. The milestone was made possible in part by Bühler’s pre-qualification and adaptation support, which ensured an efficient technology transfer and rapid operational readiness for continuous trials. This achievement is a testament to the commitment of all partners involved and signals further collaborations for Pow.Bio as it scales its innovative technology with global industry leaders. Pow.Bio will provide additional results and a case study in the upcoming weeks.