Bioprocess Optimization
From Strain to Scale
TFTAK brings deep expertise in microbial fermentation process development, from strain characterization through scale-up, built on two decades of experience in detailed metabolic analysis and bioprocess optimization since 2004. Our team has developed and optimized fermentation processes for some of the world's leading industrial strain manufacturers, drawing on years of hands-on experience with complex microbial systems.
Depending on client needs, we apply a range of cultivation approaches. We are well equipped and experienced in handling a wide variety of microbial species, from strict anaerobes to fully aerobic organisms, and offer small-scale prototyping capabilities up to 70 L with a full suite of downstream processing equipment supported by food application testing.
Approach and Work
Focus and Advantages
Solutions and Technology
Tailored Solutions
Smart Cultivation
Approach and Work
TFTAK is your ideal bioprocess optimization and development partner. We are focused on offering agile solutions and you will enjoy three major advantages while working with us:
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Open collaboration model
We work closely with you throughout the project, sharing data, results, and decision points as they arise rather than only at the end. This transparent, hands-on collaboration lets you steer priorities in real time and ensures the final process reflects your specific goals.
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Detail-oriented and flexible
Every species and every client requirement is different, so we don't work from a fixed template. Our team combines rigorous, in-depth analysis with the flexibility to adapt methods, media, and cultivation strategy as the project evolves.
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Full pipeline adapted to your specific needs
We cover everything from strain characterization – genome, growth media, and limitations – using high throughput screening. From there, we scale cultivation in bioreactors ranging from 1 to 70 L, manage the full downstream processing, and, where relevant, transfer the material to our food product development team for application testing.
Bioprocess Optimization
Focus and Advantages
Our microbial bioprocess team provides a detailed description of microbial physiology under industrially relevant conditions.
Physiological changes reveal us what is happening in the cells and suggest what could be changed. Carbon and nitrogen balances ensure quantitative reliability – we track molecules! We focus on discovering mechanisms first, enabling completely novel solutions, rather than swapping rich medium components for quick improvements with little understanding of why they occurred. TFTAK clients gain a deeper understanding of their process – value that continues long after the project ends.
Our work follows three main steps:
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Genome analysis.
We determine metabolic properties from the genome sequence. In parallel, we construct functional metabolic pathway maps and metabolic models. This helps us gather essential information about potential auxotrophies ahead of the medium development phase.
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Medium development for high-density culture begins with small-scale screening (MTP, shake flask, isothermal microcalorimetry).
Care is taken to avoid indirect effects of medium components, such as changes in buffering capacity. Lower substrate concentrations are generally preferred. Once the main components are defined, the medium is developed in bench-scale bioreactors (1–2 L) at higher substrate concentrations. We closely monitor metabolic changes to identify factors limiting growth or product titer. The cultivation mode (batch, fed-batch, etc.) is chosen to reduce substrate inhibition and unwanted metabolic by-product formation. The result is a first working process with a defined duration and product titer, and a clear understanding of its critical factors.
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Scaling and downstream processing.
The next step is scaling to steel bioreactors (7 L or 70 L), focusing on the downstream process and product prototype production. A wide range of in-house processing equipment allows us to choose exactly which steps are necessary. We determine processing losses at every step, ultimately providing input for calculating the effect on the prototype’s cost price.
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Filamentous Fungi
Solutions and
Strenghts
Filamentous fungi are one of the most versatile chassis in bioprocessing – capable of producing nutritional, protein-rich mycelium biomass as well as functional ingredients across multiple industries. We've established a dedicated laboratory for growing filamentous fungi, using both submerged and solid-state fermentation.
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We focus on:
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Alternative protein – mycelium-based biomass is considered a leading solution for providing alternative protein with a high digestibility score and functional properties.
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Biofertilizers and biofungicides – fungal strains developed for agricultural applications, supporting soil health and biocontrol.
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Functional ingredients – fungal-derived compounds for nutraceutical or specialty ingredient use.
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Solutions offered by our team at TFTAK:​
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End-to-end process design – from strain and feedstock selection through to a scaled, production-ready fungal bioprocess, not just individual steps in isolation.
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Fermentation technology – submerged fermentation, scalable from 1 L up to 70 L stirred-tank and airlift bioreactors, and solid-state fermentation in bags or trays, matched to feedstock and application.
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Metabolic characterization and growth medium optimization, grounded in our understanding of fungal metabolism, to maximize biomass yield.
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Comprehensive biomass characterization – chemical, physical, and sensory – using our in-house analytical methods and equipment.
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Post-treatment, formulation, and product development – including RNA reduction, to carry a fungal ingredient from optimized biomass into a finished product for food applications.
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Our main strengths:
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Full-pipeline process design – we take a project from strain and feedstock selection through to a scaled, production-ready process, rather than offering isolated services.
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Bioinformatic strain characterization, using our fungal genome assembly and metabolic modelling expertise to guide process optimization.
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Comprehensive in-house analytical equipment and proven up-scaling from lab to pilot to industrial scale.
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Precision Fermentation
Tailored
Solutions
Natural ingredients produced using fermentation:
In recent years, TFTAK has placed a strong focus on precision fermentation, as this technology holds great promise for addressing several key challenges in our food systems. By producing natural ingredients with the help of microbes, we can generate healthy, specialty food ingredients that are more sustainable and cost-effective.​
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Solutions offered by our team at TFTAK:
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Prototyping: We investigate whether your idea can be produced through precision fermentation, giving you an initial assessment of the project feasibility.
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Improving productivity: TFTAK applies strain engineering to optimize the performance of production strains towards commercial viability, keeping an eye on parameters important for the production process.
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Bioprocess development: TFTAK applies its extensive knowledge in fermentation modes to achieve optimal titers, yields, and cost-effective operations.
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Integrated approach with our food development teams: By leveraging our long-standing expertise in food products, the ingredient can be tested in real world applications up to the pilot-scale level.
Our own unique flavor of precision fermentation technology:
We are actively developing proprietary technology to streamline strain screening, utilizing our skilled team and state-of-the-art facilities. This approach focuses on rapid screening of combinatorial changes in cell metabolism, offering the following key advantages to our clients:
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Improve strain productivity by screening 1000-fold deeper into the cell metabolism than current techniques in the field.
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Identify non-obvious strain engineering combinations, which will generate novel IP or can circumvent existing IP, enabling our clients to enter markets comfortably.
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Reduced strain development times and costs through a lower reliance on expensive robotics and automation.
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Cultivation equipment
TFTAK's modern laboratory is equipped with state-of-the-art equipment, enabling us to provide our clients with high-quality and reliable service – for a more detailed overview of our equipment, click here.
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Bioreactors and cultivation equipment with online gas analysis
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Bench top class (1L, 2L) and stirred tank steel bioreactors: (7L, 70L)
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3.5 L airlift bioreactor
Screening equipment
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Isothermal microcalorimeters (IMC, in total 70 channels)
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Microtiter plate reader
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Shaker incubators
Downstream processing equipment for 50L culture volume
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Liquid/solid separation: Disc stack and decanter centrifuge
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Cell disruption: high pressure homogenizer
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Purification: micro-, ultrafiltration
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Drying: Spray and freeze-drying equipment​
We make biology make sense!
"Our microbial bioprocess team pays close attention to detail, always eager to learn how microbes function. We have achieved outstanding results in collaboration with world-leading companies by providing fresh perspectives and deeper insights – all applied to robust, scalable process development."
Ranno Nahku, PhD
R&D Director in Biotechnology