Reducing Waste in Bioreactors
Traditional bioreactors are large, permanent stainless-steel systems used in full-scale drug manufacturing. However, smaller single-use bioreactors, often made of plastic, are commonly used in research labs and early-stage production. These disposable units can range from a few liters to a couple hundred liters and are faster to set up, eliminating the need for complex sterilization routines and making it easy to test different drug formulas without cross-contamination. But once used, they’re usually thrown away, contributing to the growing concern of long-term sustainability.
The Need for Change
The increasing use of single-use technologies (SUTs) like disposable bioreactors has raised concerns about long-term sustainability. Even though they make up only a small portion of global plastic waste, their growing use has led to the accumulation of waste that can have detrimental effects on the environment. The biopharma industry is a significant contributor to this problem, and there is a need for change.
The Role of 3D Printing
3D printing offers major advantages in this space. It allows highly customized parts to be made without traditional molds or tooling, which is particularly useful for parts that must be chemically stable, resistant to high temperatures, and compatible with living cells. 3D printing also opens the door to creating only what’s needed, cutting down on waste.
- One of the key parts of Project Nexus is combining 3D printing with newly developed bio-based materials, making some parts reusable.
- The project aims to make parts that can be cleaned and reused using high-heat sterilization, offering the convenience of single-use systems but with less waste.
Developing Sustainable Materials
Photocentric, a company known for its resin-based 3D printers, is supplying its newest system, called JENI, to help create these next-generation tools. JENI is a large, industrial-scale, modular 3D printer for high-speed, high-volume production. The researchers are also working on new sustainable, bio-based thermoset resins that can be printed into shape and then hardened to become strong, stable, and reusable.
“Our focus on circularity and end-of-life solutions ensures that this project not only advances technological capabilities but also drives meaningful progress towards net zero goals. We look forward to collaborating with our partners to redefine the role of additive manufacturing in the sector,” stated Tony Jackson, director of formulation at CPI.
The Potential for a Greener Biopharma Industry
Single-use technologies (SUTs) like disposable bioreactors are widely used in biopharma because they’re quick to set up, flexible, and eliminate the need for deep cleaning. However, their growing use has added to the problem of long-term sustainability. By developing reusable parts and sustainable materials, Project Nexus aims to make a significant impact on the biopharma industry.
- Big Impacts, Small Waste: Single-use technologies (SUTs) like disposable bioreactors are widely used in biopharma, but their growing use has added to the problem of long-term sustainability.
- The team sees room for improvement, as waste from SUTs currently makes up only about 0.002% of global plastic waste.
- Project Nexus wants to keep all the benefits of SUTs, such as speed and flexibility, while improving sustainability with better materials and reusable parts.
A sustainable approach to bioreactors can have significant benefits for the biopharma industry. By reducing waste and using renewable resources, companies can save water, energy, and harsh chemicals. Additionally, reusable parts can be sterilized and reused, reducing the need for single-use technologies.
| Benefits of a Sustainable Approach | Advantages |
|---|---|
| Reduced Waste | Saves water, energy, and harsh chemicals |
| Reusable Parts | Reduces the need for single-use technologies |
| Sustainable Materials | Reduces the impact of plastics on the environment |
The components developed through Project Nexus will go through real-world testing. First, they’ll be tested in pharmaceutical research labs and small-scale manufacturing setups, like point-of-care facilities where medicines are made on-site. Later, the team hopes these technologies will move into industrial biotechnology, including green chemical production.
The biopharma industry has the potential to play a significant role in reducing plastic waste and promoting sustainability. By developing reusable parts and sustainable materials, Project Nexus aims to make a significant impact on the industry. With its full-system approach, the project is expected to make progress over the next two years. As the work progresses, researchers will assess how well the 3D printed parts perform—not just in the lab but economically and environmentally. The goal is to make sure the new tools aren’t just greener in theory but truly sustainable in practice.
