Model development for systematic media optimization for bioprocesses

The Fraunhofer Innopush program, funded by the German Federal Ministry of Education and Research (BMBF), aimed to provide a one-time cushion against the economic downturn caused by the COVID-19 pandemic and to stimulate innovation in the economy. Innopush projects were designed to structure and promote innovative, cross-institutional initiatives that, on the one hand, address competencies particularly affected by the current economic crisis, and on the other hand, generate added value through the collaboration of diverse expertise to secure the future and support the economic recovery. Biotechnology is part of the Fraunhofer-Gesellschaft's strategic research field "Bioeconomy": The production of novel substances using living organisms is intended to cure the sick, replace increasingly scarce raw materials, and make our lives easier and more comfortable. Over the past 30 years, digitalization has significantly increased profitability and quality and reduced time to market in the chemical industry. This potential is currently only partially recognized or utilized in most bioprocesses and related companies.

The goal of the Innopush project DiBi was to develop a software-based decision support system for the optimized operation of bioreactors using plant cells, demonstrated through a concrete application: the production of protein-based growth factors/signaling molecules for the differentiation of therapeutic cell products.

A key methodological component of the project was the integration of model-based multi-objective optimization, experimental trials in parallelized formats, and an appropriate sensor and analytics setup. The Fraunhofer ITWM, with its expertise in modeling, simulation, and optimization of complex process engineering systems and agile software development, collaborated with the Fraunhofer IME and ITMP, contributing their competence, laboratory infrastructure, and industry knowledge.

This collaboration aimed to develop a new methodology for industrial users, made accessible through a software prototype featuring the required algorithms and interactive graphical interfaces. The improvement potential of the underlying processes was to be transparently identified, quantified, and evaluated. Reliable in silico evaluation of “what-if” scenarios was also made possible.

The functionality and benefits of this software prototype were to be demonstrated using the aforementioned process, providing practical user stories and pitches to help engage potential industrial partners for future cooperation.