Process optimization: From petrochemicals to biopharmaceuticals

Process optimization methods and tools developed for petrochemical plants also can be used successfully by biopharmaceutical manufacturers. In this white paper, Bayer Technology Services (BTS) describes adapting methods for semi-batch biotech processes that the company had developed earlier and used successfully for large continuous polymer processes. Case studies show how BTS adapted computer simulation and total performance optimization for its pharmaceutical and biotech processes.

BTS developed optimization for chemical processes by focusing on improving key performance indicators (KPIs) and basing its methodology on Six Sigma's stepwise DMAIC approach (define, measure, analyze, improve and control the process). BTS found that chemical and biotech processes shared basic features. Reactor kinetics should be associated with cell metabolism, reaction with fermentation, and distillation with chromatography.

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