BIOPROCESSING AND BIOPROCESSES: FROM LAB TO INDUSTRY - 2026/7

Module Overview

The module is directed to the study of large-scale bioprocessing and bioprocesses, from foundations to real industrial cases. The module shows how the principles studied in the previous module are applied in scales typical of pilot plant or industry, in particular the pharmaceutical, food, and chemical industries.

Module provider

School of Biosciences

Module Leader

AVIGNONE ROSSA Claudio (Biosciences)

Number of Credits: 30

ECTS Credits: 15

Framework: FHEQ Level 7

Module cap (Maximum number of students): N/A

Module Availability

Semester 1

Prerequisites / Co-requisites

None

Module content

Indicative content includes:
Lectures and captured content:

• Microbial biotechnology. Classic and Advanced Bioprocesses, Different systems for cultivation of microorganisms: Methods and strategies.

• The dynamics of microbial growth and its link to product formation: Kinetics and stoichiometry of cellular growth.

• Introduction to Chemical and engineering principles.

• Industrial scale equipment.

• Scaling up criteria and industrial bioprocess design.

• Experimental design, modelling and data analysis.

• Machine learning for bioprocess optimisation.

• Enzyme technology, Biocatalysis and Bioconversions.

• AI-powered process simulation; Downstream process optimisation.

• Dynamic Techno Economic Analysis.

• Bioanalytical methods and ¿omics analysis in bioprocesses.

Problems and data analysis:

• Problem solving classes and tutorials on microbial kinetics, calculation of culture parameters, design of batch, fed-batch and continuous cultures.

• Computer classes for process modelling and simulation.

• The data for analysis will be obtained in a long-term experiment (continuous culture of a microbial strain) where the growth of a model microorganisms will be studied. This will involve all the steps needed for the experiment, from selection of strain to product analysis. The students will contribute to the preparation of the seed cultures and inoculation of starter cultures, operation of mini-reactors, sample taking and analysis, data analysis and calculation of product rates and yields, and data analysis and write up of report.

Assessment pattern

Alternative Assessment

None

Assessment Strategy

In this module, the assessment strategy will give students the opportunity to demonstrate ability to understand, analyse and explain the use of basic principles to design criteria for their application in real-world scenarios.
This will be reflected in an essay covering a bioprocess (real or fictitious).
The summative assessment for this module consists of:

• Two problem-solving exercises.

• One essay on large-scale bioprocess design.

Formative assessment and feedback: Discussion of industrial cases and published data will facilitate the development of scientific and technical writing skills. (4 x 1h sessions). Written feedback will be given whenever possible, and verbally during seminars and tutorials. Feed-back on drafts will be provided to sequential versions of essays and reports, which will be treated as ¿living documents¿ until submission.

Assessment activities have direct impact on employability, allowing the students to hone their skills for report writing, large-data analysis, and use of computational tools.

Module aims

• Provide specialized study on the principles involved in scaling-up biological processes, and the problems specific to the use of biological agents.
• Study in detail how physico-chemical factors and operational conditions can modify the metabolic and physiological mechanisms observed at laboratory scale, and how those can be manipulated to drive the production of compounds of interest at large scale.
• Understand the criteria used for isolation, separation and purification of a range of biological compounds produced by the biotechnological and biopharmaceutical industries.
• Introduce novel approaches and strategies for the rational design of large-scale processes.

Learning outcomes

Methods of Teaching / Learning

The learning and teaching strategy for this module has been designed to facilitate the integration of different subjects and their link with subjects discussed in module 1 (Cell Factories: From Exploration to Exploitation). Industrial-based case studies will be used to illustrate the different themes under discussion, highlighting the different aspects included in bioprocess design. There will be milestones and deliverables to be reached throughout the course, ensuring the students acquire the expected competencies and skills.
Similar to module 1, the learning and teaching methods include a combination of:

• Data analysis, calculations and computational models applied to bioprocess design.

• Use of specialized software and simulation tools to facilitate understanding of large-scale processes, from up-stream to down-stream.

• Tutorials and problem-based exercises with flexible format to facilitate interaction between peers, and between students and teaching and technical staff.

• Tutorials to test understanding and comprehension of the content of the module, and to facilitate the write up of the assessment essay. Scheduled and on-demand sessions will be available to discuss any issues related to the assessment and to improve the understanding of the problems under study.

Indicated Lecture Hours (which may also include seminars, tutorials, workshops and other contact time) are approximate and may include in-class tests where one or more of these are an assessment on the module. In-class tests are scheduled/organised separately to taught content and will be published on to student personal timetables, where they apply to taken modules, as soon as they are finalised by central administration. This will usually be after the initial publication of the teaching timetable for the relevant semester.

Reading list

https://readinglists.surrey.ac.uk
Upon accessing the reading list, please search for the module using the module code: BMSM046

Other information

The contribution of the module to the 5 pillars can be described as follows
Digital capabilities: The students will have access to standard software and digital tools, and to specialized computational and modelling tools for the design of bioprocesses, scaling-up, separation and purification of compounds of interest, etc. The students will also have access to industrial data and the use of statistical tools on-line for data analysis. There will be an introduction to machine learning approaches for design and analysis of large-scale bioprocesses.
The module will make use of diverse platforms for communication, discussion groups, social media, etc.
Sustainability: The module will familiarize the students with biotechnological approaches to design green, sustainable bioprocesses that should reduce our demand for fossil fuels, and the consequent reduction in greenhouse gases release. As described elsewhere, Biotechnology underpins sustainable processes, and as such will promote the engagement of students in the UN¿s Sustainable Development Goals.
Resourcefulness and resilience: Some of the subjects involved in this module require the revision and acquisition of basic knowledge not necessarily treated in regular UG courses. The students will have to dedicate time and effort to understanding some of the mathematical, chemical, and physical concepts essential to this module. This will demand organization and planning skills.
Global and cultural capabilities: As mentioned earlier, we expect our students to possess different background knowledge and expertise, creating a culturally and socially heterogeneous group, with different points of view and approaches in relation to industrial processes. This situation will give the students flexibility to understand the problems and hurdles suffered by industry in different parts of the world.
Employability: Again, subjects and approaches developed in the module will give the students a solid background, up-to-date knowledge, and hard skills and soft skills suitable for the pharmaceutical, biotechnological, and environmental fields.

Please note that the information detailed within this record is accurate at the time of publishing and may be subject to change. This record contains information for the most up to date version of the programme / module for the 2026/7 academic year.