Back to: MICROBIOLOGY 400 LEVEL
Welcome to class!
Hello, future scientist! I’m excited to have you back again. You’ve been learning some amazing things about industrial microbiology, and today’s topic is where the real-world application becomes even clearer. We’re talking about Scale-up from Lab to Pilot and Industrial Scale. This is the journey every successful fermentation product must take—from small experiments in the lab to full-blown production in factories. It’s like going from cooking one plate of jollof rice at home to making enough to feed an entire school!
Scale-up From Lab To Pilot And Industrial Scale
What is Scale-up?
Scale-up is the process of increasing the size and capacity of a fermentation system while keeping the results consistent. It starts with small laboratory experiments (using flasks or small fermenters), then moves to medium-sized systems (pilot scale), and finally to large fermenters in factories (industrial scale).
It’s not just about using bigger containers—it involves adjusting and controlling many factors to ensure the microorganisms behave the same way at every stage.
Stages of Scale-up
1. Laboratory Scale
This is where the initial research happens. Scientists test different microorganisms, growth media, temperatures, pH, and oxygen levels in small flasks or benchtop fermenters (usually 1–10 litres).
Purpose: Discover the best conditions for growth and product formation.
Challenges: Results are small, and not all conditions will translate well to larger systems.
2. Pilot Scale
After successful lab results, the process is tested in pilot fermenters (about 50–500 litres). These are like “mini-industrial” systems.
Purpose: Test how the microbes perform in larger volumes and how the control systems (for pH, temperature, oxygen, etc.) work.
Why it matters: This stage helps identify problems that could occur on a larger scale. For example, mixing and oxygen transfer might not be as effective in a bigger tank.
3. Industrial Scale
This is full production—thousands of litres! Fermentation takes place in large bioreactors (10,000 litres or more), and the product is made for commercial use.
Purpose: Maximise product yield efficiently and economically.
Requirements: High-quality process control, strict hygiene, and trained personnel.
Factors to Consider During Scale-up
Mixing and aeration: It’s harder to mix and deliver oxygen evenly in large tanks, so stirrers and spargers must be properly designed.
Heat transfer: Microbes produce heat as they grow. In larger systems, it becomes harder to remove excess heat.
Shear stress: Stirring too fast can damage fragile cells, so agitation must be balanced.
Sterility: Contamination at large scale can lead to huge losses, so everything must be properly sterilised.
A Nigerian Example
Let’s say a university lab in Ibadan discovers a bacteria strain that produces a powerful new enzyme using palm kernel waste.
In the lab, the researchers grow the bacteria in small bottles.
At the pilot stage, they test it in a small fermenter in partnership with a local food processing company.
If the results are consistent, they partner with an industrial facility in Lagos to produce the enzyme at scale for use in detergents or food processing.
Summary
- Scale-up is the step-by-step increase from small lab research to full-scale production.
- It involves laboratory scale (small), pilot scale (medium), and industrial scale (large).
- Challenges include mixing, heat transfer, oxygen supply, and maintaining sterility.
- Each stage helps refine the process to ensure high-quality, consistent product output.
- Scale-up makes it possible to turn a scientific idea into a real product available in the market.
Evaluation
- What are the three main stages in fermentation scale-up?
- Mention two technical challenges that occur when moving from lab to industrial scale.
- Why is the pilot scale necessary before going fully industrial?
You’ve just learnt how a tiny microbial experiment can grow into a big industry-changing product. Always remember, the future of science and innovation in Africa includes you. Keep shining, keep learning, and Afrilearn is proud to be part of your journey. See you in the next class!