Next-Generation Biotechnology and Bioprocess Engineering for Scalable Bioengineering Applications

Abstract

The increasing demand for sustainable and scalable biomanufacturing requires integrated advances in biotechnology and bioprocess engineering. This study aims to develop and evaluate a next-generation bioengineering framework that combines engineered microorganisms, scalable bioreactor operation, advanced process control, and energy-efficient design. The methodology integrates genetic engineering of microbial hosts, controlled fermentation across multiple bioreactor scales, systematic analysis of substrate utilisation, and comparative evaluation of conventional, model-predictive, and AI-driven control strategies. The results demonstrate that product yield increased nonlinearly with scale and stabilised at approximately 5.3–5.6 g/L at bioreactor volumes of 800–1000 L, indicating successful scale-up without loss of productivity. Cell growth kinetics followed a robust sigmoidal profile, with normalised cell density reaching 0.95–1.0 within 55–72 h. Optimal substrate concentrations above 60 g/L resulted in maximum product formation rates of 35–42 g/L/h. Among control strategies, AI-driven control achieved the highest process efficiency (~95%), outperforming model predictive control (~88%) and conventional PID control (~75%). Energy consumption decreased significantly with scale, from >60 kWh/kg at small scale to ~8–10 kWh/kg at production outputs exceeding 400 kg/batch. Overall, this study demonstrates that integrating intelligent control with scalable bioprocess design significantly enhances productivity, energy efficiency, and sustainability, providing a viable pathway for industrial-scale bioengineering applications.