Productivity and Cost-Saving Benefits of Single-Use Bioprocessing

The popularity of single-use bioprocessing (bioreactors and fermenters) has grown in recent years, aiming to meet the ever-increasing industry demands of higher productivity and lower costs. But compared to traditional stainless steel systems, can these disposal solutions really deliver on their benefits? And in a world concerned with reducing their energy and environmental footprint, can their use ever be sustainable?

Productivity and efficiency

One of the main benefits of switching to single-use solutions is the increased productivity. According to Justin Cesmat, Bioprocessing Product Line Manager at Distek, single-use products can help expedite bioprocessing operations in several ways. Firstly, “single-use bioreactors are typically pre-sterilized and ready to use,” reducing the complex and time-consuming cleaning processes associated with the setup of traditional equipment. “Additionally, single-use solutions can be easily integrated into existing bioprocessing workflows,” meaning that the installation is quick and simple even if it is your first time using or you are changing product lines.

The smaller footprint of single-use equipment is also a valuable benefit—allowing manufacturers to make more efficient use of their available floorspace and precisely develop product to balance customer demand, adds Jordan Cobia, Product Manager, Thermo Fisher Scientific.

Once in use, the disposable nature of single-use means that the extensive sterilization and validation steps between production runs are eliminated—reducing the downtime between batches and allowing for rapid product changeover. “Validation costs and time requirements for stainless steel are significant and can lead to reduced annual batch quantities. Single-use removes that from the equation,” Cobia explains. Furthermore, this reduction of resource-heavy cleaning, frees up the previously occupied staff to complete other, more productive activities—creating more time for science.

Flexibility

Flexibility is another key benefit of single-use solutions and can further increase productivity. While conventional bioreactors are limited by their single design, “single-use bioreactors are available in a range of sizes and configurations,” notes Cesmat, meaning that it is easy to experiment with various designs to optimize production. “Unlike reusable systems, single-use solutions can also be easily customized,” he continues, confirming that tailor-made production equipment is within easy reach. Such flexibility is critical in enabling “end users to scale and develop product to balance customer demand,” summarises Cobia and makes “single-use manufacturing a simple decision for manufacturers.”

This flexibility would also prove invaluable if your production needs change. While recycling of traditional equipment requires expensive melting processes, single-use systems can be quickly and easily disposed of—ensuring that changing production is fast and inexpensive, with none of the restrictions of rigid, application-specific stainless-steel vessels.

Cost savings

Reduced costs are another key benefit attracting bioprocessing industries to single-use solutions. Compared to traditional equipment, single-use solutions are cheaper and easier to install—reducing initial capital investment. They also eliminate the extensive maintenance and cleaning measures required by traditional equipment—reducing labor, material, and operating costs. In addition to reducing costs, the increased productivity and output from single-use solutions can also lead to enhanced revenue—and when both are combined, they can dramatically impact a company’s bottom line.

Reduced contamination

Another “major benefit that drives the adoption of single-use solutions is that the contamination risk is reduced,” Cobia says. In traditional bioprocessing, the risk of cross-contamination means that major investments are needed to complete the extensive steam in place (SIP) or clean in place (CIP) procedures required to mitigate the risks. Since single-use solutions are self-contained; arriving pre-sterilized and discarded after each use—they effectively eliminate the risk of cross-contamination, and with it the cost of cleaning, and of ruined batches.

Reduced energy and water use

While the benefits of single-use bioprocessing are obvious, with a worldwide drive to reduce waste and energy can using single-use products be sustainable? “Single-use solutions have been criticized for their environmental impact, as they generate more waste,” Cesmat says, however the question of whether they are indeed less environmentally friendly is not so straightforward.

While traditional stainless steel equipment demands vast water and energy consumption to complete the necessary cleaning and sterilization, single-use solutions eliminate this requirement—leading to a significant reduction in total water, energy, and chemical usage. This coupled with the reduced facility size that single-use solutions allow, means that they offer a reduced overall environmental footprint.

In addition, the disposal of single-use solutions can actually generate energy—their incineration releases stored energy that can be harnessed for heat or electric generation. Manufacturers are continuing to work to ensure single-use vessels can be effectively recycled; moving to materials that can be reused in the form of many other plastic items. So, while “the name single-use does not bring sustainability to the top of your mind,” admits Cobia—single-use solutions could in fact be exactly that.

Conclusion

While conventional reactors have traditionally dominated bioprocessing, the increased productivity, flexibility, cost-savings, and reduced contamination risk of single-use solutions have made their use skyrocket in recent years.

Manufacturers of such single-use solutions are also working hard to respond to the ever-increasing scrutiny placed on the green credentials of scientific products—reducing their environmental footprint and with it the reasons for not choosing them. And as Cesmat predicts, we can expect an even “greater emphasis placed on sustainability, and specifically recycling programs for single-use” in the future. So, with less criticism for their environmental impact, as well as the obvious benefits, will this mean the end for traditional bioprocessing?

Key Takeaways

• Increased Productivity: Single-use bioprocessing solutions offer expedited operations, pre-sterilization, and easy integration into existing workflows, reducing setup time and complexity.
• Flexibility and Customization: Unlike traditional stainless steel systems, single-use solutions provide a range of sizes, configurations, and customization options, allowing for optimization of production and easy adaptation to changing production needs.
• Cost Savings: Single-use solutions are cost-effective due to lower initial capital investment, elimination of extensive maintenance and cleaning measures, and increased productivity and output, leading to enhanced revenue and profits.
• Reduced Contamination Risk: Single-use systems eliminate the risk of cross-contamination, as they arrive pre-sterilized and are discarded after each use. This mitigates the need for extensive cleaning procedures and safeguards against ruined batches.
• Environmental Sustainability: While single-use solutions generate more waste, they significantly reduce water, energy, and chemical usage compared to traditional stainless steel equipment. The smaller facility size and potential for energy generation through incineration contribute to an overall reduced environmental footprint.
• Growing Popularity: Single-use bioprocessing solutions have gained traction, particularly in drug development and manufacturing, due to their proven benefits in productivity, flexibility, cost savings, reduced contamination risks, and potential sustainability advantages.