Explore how BioMADE is securing the future of the US through bioindustrial manufacturing innovation
While ‘biotechnology’ and ‘bioindustrial manufacturing’ may sound like new concepts, in fact, the processes are based on fermentation, which was first harnessed by humans over 10,000 years ago. Today, innovative American companies are using advanced biological processes to safely manufacture everyday products ranging from chemicals and materials, to plastics, textiles, and more. Yet, many believe that the US currently lacks the pilot-scale biomanufacturing infrastructure to assist these companies in scaling up their biobased products from the lab bench to full commercialization.
With a vision to address this infrastructure shortage and build a sustainable, domestic end-to-end bioindustrial manufacturing ecosystem, in 2020, the US Department of Defense created the Bioindustrial Manufacturing And Design Ecosystem, or BioMADE, to develop technologies that enhance American competitiveness in the bioindustrial sector. The Institute’s innovations are designed to mitigate investment risks in relevant infrastructure and expand the biomanufacturing workforce. Jill Zullo, Executive Vice President and COO, shares comprehensive insights into BioMADE’s mission and the ongoing development of its pilot-scale bioindustrial manufacturing facilities.
“BioMADE is a membership organization and a public-private partnership, originally catalyzed by the Department of Defense in October 2020 and fully launched in April 2021. As a membership organization, we have over 325 members from across the US, including large leading companies, such as Cargill, Lockheed Martin, and Black & Veatch, as well as start-ups, small businesses, nonprofits, and a variety of universities and community colleges. We were established to address national security concerns related to biomanufacturing and to accelerate its development within the US market. While we are particularly focused on the domestic market, we also engage with global companies,” she begins.
Supporting technological innovation is at the heart of BioMADE’s operations, though the company specializes in a specific level of innovation. The Technology Readiness Levels (TRLs) are tools used for evaluating technology, ranging from one to nine, with lower numbers indicating discovery and initial proof of concept, and a score of nine representing full commercialization. “The area of innovation we focus on lies within the TRL range of four-to-seven. As an Institute, we were created to assist companies in transitioning from proof of concept to piloting and demonstration, thus enabling them to make commercial investments and be successful. We cover the space in between early stage and commercialization, which is sometimes called the Innovation Valley of Death. Usually, companies have enough resources to prove their ideas, but the difficulty lies in taking this promising concept from the laboratory to commercialization, a process that requires extensive piloting and tools,” Jill enlightens.
To facilitate this transition, BioMADE is building a national network of pilot-and demonstration-scale bioindustrial manufacturing facilities across the US. Jill explains how these facilities will benefit the organization and its clients. “So far, we have announced three facilities: our flagship in Minnesota, another in California, and the latest in the state of Iowa. The reason behind the creation of this national network is that no single facility can have everything that each of our members need.”
Located in the San Francisco Bay Area, the California facility will serve as a hub for biotech and biomanufacturing, as it is surrounded by numerous startups, research institutions, and universities. Moreover, more than 60 BioMADE member organizations are located within an hour’s drive. This facility will represent the first step toward pilot-scale production, featuring slightly smaller fermenters of 4000 liters. Its key focus will be on chemicals and materials, like lubricants, paints and coatings, and lightweight composite materials.
“Our Iowa facility will be the next scale up, equipped with 5000 to 10,000 liter fermenters. This facility will be food-grade, meaning we can make products like probiotics, prebiotics, flavors, sweeteners, and nutritional supplements, as well as other agricultural products. We love Iowa’s positioning; this facility is just a few miles away from Iowa State University and near facilities that convert corn into liquefied feedstocks. Consequently, we can easily utilize commercial feedstocks in Iowa. As we begin operating the 10,000 liter fermenters and progress through the piloting confirmation phases, we will be able to implement all the processes used within a commercial production facility, which is important for demonstrating the robustness of our techniques.”
Meanwhile, BioMADE’s Minnesota facility will be its largest. “We have purchased a 120,000 square foot building, which we are establishing as our flagship
demonstration facility. Although it will have some smaller fermenters, it will also include our largest fermenters, with a capacity of 25,000 liters. The facility will focus on chemicals and materials, such as anti-corrosive lubricants and high temperature-resistant composite materials, and will have explosion-proof capabilities. There, we will have the ability to produce fuels and ignition components, all products that might be needed in the wider bioeconomy. We are also mindful of our key investor and funder, the Department of Defense, which has several projects of interest that require scaling up various technologies. Our Minnesota facility will be fully capable of producing what they need at a commercial level,” Jill adds.
In addition to the fermenters, BioMADE will integrate different technologies in its pilot-scale facilities, including downstream equipment designed to separate cells from the fermentation broth. After this step, the equipment will enable the concentration and further purification of the main products by removing various salts and byproducts from the fermentation process. The organization plans to begin with standard unit operations and equipment that facilitate the purification and concentration of the broth before considering the implementation of other equipment. Depending on the specific facility, BioMADE may incorporate crystallization and spray drying capabilities or collaborate with partners in the area who can provide additional unit operations. Given the complexities of starting a pilot facility, BioMADE will initially focus on the most ubiquitous and versatile pieces of equipment. As the organization starts to gain a clearer understanding of its operational needs, it can rent specialized equipment or partner with local companies that possess the necessary resources.
“One of the initiatives we can implement at our Minnesota facility, with a view to expand it to all sites, involves investing in innovation, as some of our members are developing exciting new sensors that are very helpful for our operations. They are working on a different configuration for continuous fermentation processes as well as specialized downstream techniques that assist in removing any crystal product as it is being formed. Our members are coming up with all sorts of innovative unit operations and modifications to standard processes, and we have already supported the funding of the equipment they need. We are also saving space for unique, novel technologies to test and demonstrate, which can serve as examples for other customers. This commitment to innovation is a significant part of what we are doing in Minnesota,” Jill concludes.
As a proud Manufacturing USA® member, BioMADE is advancing domestic bioindustrial manufacturing by closing gaps in pilot- and demonstration-scale infrastructure. The Institute partners with manufacturers and innovators to advance technologies while training a robust domestic workforce for manufacturing jobs across the industry. Through these efforts, BioMADE is positioning the US as a leader in bioindustrial innovation and competitiveness.