Team:FCB-UANL/Implementation
We proposed a scale up process for industrial production, as a complement to the entrepreneurship section. As well, we determined some of the safety considerations to take into account during the upscaling of the project, and some initial entrepreneurship aspects to better understand how our product will reach the desired customers.
PRODUCTION PROCESS
Production
Although we will first work with two separate cultures during the development of the project, we plan to make in a future a co-culture of both strains of E. coli expressing Rsn-2 and Rsn 3-5. These proteins can be produced in a batch bioreactor, as it is intended for surfactin production also. On the other hand, for biofilm production, a rotork bioreactor is needed, which needs to undergo a batch process and it functions as a centrifuge.
Separation and preparation
As part of the industrial process, we need to separate the biomass from culture media. To do so, we plan to use a centrifuge for biomass separation. Once the biomass is separated, it can either be used to feed the bioreactors as organic matter or proceed with the preparation for the extraction of the desired components.
Extraction of components.
Ranaspumins.
To extract these proteins from the bacterial strains, we use a cellular lysis procedure. After the procedure is completed, the crude extract is stored.
Surfactin
In the case of surfactin, we use the cell culture without biomass for hexane solvent- extraction, followed by a filtration to remove cells from the components and later evaporate the solvent. The solid extracts are then stored.
Biofilm
After biomass separation, the extraction of Exopolysaccharide matrix (EPS) is performed by an acetate-acid precipitation reactor, a mechanism in which we expect to kill the remaining cells attached in EPS and to propitiate polymer precipitation. Within the process, we also considered a step to sterilize the mix, either by filtration or heat.
Mixing and dispenser.
The last step of the process is the formulation of the foam and its mixing. All the components are blended with the help of a reactor with mixing blades. The component concentrations are uncertain before testing, but we summarize the components in the following table.
After a homogeneous phase is achieved, the mix must be dispensed into the polypropylene containers and etiquetting.
The foam must meet many requirements to ensure the clients and safety protocols’ needs. Some of them must be accomplished before lot selling, and those are enlisted in the following list:
- Foamability: Testing the velocity and amount of foam that can be produced under certain conditions.
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Crude mix stability, which can be divided into two:
- Chemical stability: Chemical degradation and oxidation may affect the foam effectiveness.
- Biological stability: As the foam is made from biodegradable components, it promotes biological growth and disintegration, and this may affect the foam effectiveness and foamability.
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Foam stability: It is measured when the foam is used.
- Drainage flow
- Heat resistance
- GMO free tests
- Foam Expansion quality
- Conductivity
- Biodegradation tests
- Security tests
Nowadays, bioreactors are the most standardized way in which chemicals are produced with the use of industrial biotechnology, and their application under the right conditions allows them to handle GMOs safely. Therefore, the bio-containment strategy focuses on the implementation of the GMO using one of these devices in the future, after the planned experimentation. The most likely scenario in which our organism may be accidentally released is during the operation and maintenance of the bioreactor, process during which small volumes of the media in which the bacteria are being grown may escape as an aerosol or drops; however, the possibility of an accident where the reactor is broken and its contents are fully spilled can not be dismissed. Even though the risk level is low with proper training, constant vigilance is necessary to avoid any injury. The complete protocol for bioreactors safety is further explained in the risk assessment made as part of our safety activities.
COMERCIALIZATION
Synbiofoam provides the first production line of ABC biofoams made through synthetic biology dedicated to fighting forest fires. This helps in the process of the mitigation to mitigate fire damage and the gradual consequences of the use of fire extinguishers with foams composed of fluorosurfactants.
But, how are we going to make the product reach the end users? Customers have shown trends based on physical stores, where they can buy directly the units, as well as websites that allow them to explore other products. In both cases, the use of catalogs is a practical tool to show them more about the business. It is also considered the payment for search tools, such as Google Ads, to prioritize our ads over others, as well as distributing our foams through electronic delivery systems, all through our official platforms and social media accounts to reach our potential customers.
But, how are we going to make the product reach the end users? Customers have shown trends based on physical stores, where they can buy directly the units, as well as websites that allow them to explore other products. In both cases, the use of catalogs is a practical tool to show them more about the business. It is also considered the payment for search tools, such as Google Ads, to prioritize our ads over others, as well as distributing our foams through electronic delivery systems, all through our official platforms and social media accounts to reach our potential customers.
Although this product is mainly directed towards firefighting departments, our firefighting foam is not limited to only this type of user. As our foam is further approved and distributed, we propose the following end users who will take advantage of the useful properties of foam concentrate.
The final product the end users will have would consist of the foam’s concentrate, which contains the components produced in the bioreactors, inside a container that gives further specifications about the product. Although we need to perform practical work to get familiarized with the methods to apply the foam, we propose the application process will not be significantly different from that of traditional foams. For more information, consult the Entrepreneurship section.