Pow.Bio launches continuous fermentation facility to revolutionize biomanufacturing

By Agroempresario.com

Pow.Bio, a startup pioneering continuous fermentation for precision biomanufacturing, has unveiled a state-of-the-art facility in Alameda, California. This 25,000 sq ft FDA-registered site is equipped with advanced fermentation systems and proprietary software, allowing clients to scale production from gram-scale trials to hundreds of kilos of high-value ingredients.

By eliminating the inefficiencies of traditional batch fermentation, Pow.Bio’s technology offers a cost-effective, scalable solution that accelerates production timelines and reduces operational costs.

A New Era of Precision Fermentation

Pow.Bio’s innovative approach disrupts the conventional batch fermentation model, which requires repeated sterilization, cell growth, and harvesting cycles. Instead, the company has developed a system that maintains microbes in a high-productivity state for extended periods, significantly increasing manufacturing efficiency.

"Many promising bioproducts face challenges due to high production costs and lengthy development cycles," said Shannon Hall, CEO and cofounder of Pow.Bio. "Our new facility serves as an active demonstration site, showcasing how our technology delivers meaningful efficiency gains for our partners today."

How Continuous Fermentation Works

In traditional precision fermentation, microbes undergo a growth phase before being triggered to produce a target molecule. Once the process is complete, the batch is extracted, the tank is cleaned, and the cycle starts over. This repetitive method slows production and increases costs.

Pow.Bio’s platform separates the growth and production phases, allowing for a steady flow of microbial cells and continuous extraction of target molecules. This process minimizes contamination risks and prevents genetic drift, common issues in batch fermentation.

"We’ve broken fermentation into unit operations, focusing on growth, production, and product recovery," Hall explained. "This creates a true conveyor belt process: cells in, product out."

By integrating cutting-edge engineering into both software and hardware, Pow.Bio manages flow rates, recycles cells, and optimizes biomass control through autonomous software-driven systems.

Lower Costs, Higher Yields

Pow.Bio’s technology not only increases efficiency but also reduces capital expenditure (capex) requirements. The company designed its platform to integrate seamlessly with existing manufacturing infrastructure, eliminating the need for expensive facility overhauls.

"Most manufacturers already have the necessary equipment," Hall noted. "Our technology requires minimal modifications, making it easy for companies to transition from batch to continuous processing. This shift more than doubles production output while lowering unit costs."

For businesses aiming to scale up beyond Pow.Bio’s facility, the transition to commercial-scale production is straightforward. "Our capex-light conversion model ensures that our partners can easily implement continuous fermentation without the burden of building new facilities," Hall added.

Deployable Within Existing Systems

Pow.Bio collaborates with a diverse range of clients, from startups to multinational corporations, all seeking cost and capacity solutions.

"Our customers need to scale production efficiently and cost-effectively," Hall said. "We provide a modern biomanufacturing platform that supports both vertically integrated manufacturers and emerging product teams requiring contract manufacturing."

The new facility serves as both a proving ground for technology validation and a launchpad for companies transitioning to full-scale commercial production. With its revolutionary approach, Pow.Bio is poised to redefine biomanufacturing economics and set new industry standards for efficiency and sustainability.