Pow.Bio, Bühler, and ATV Technologies achieve breakthrough in continuous biomanufacturing at 3,000-liter scale

Pow.Bio has announced a major milestone in continuous biomanufacturing, successfully scaling its platform to 3,000 liters at ATV Technologies’ facility in Compiègne, France. The collaboration with Bühler Group and ATV produced three times more protein than an equivalent fed-batch process, marking an important step toward large-scale industrial validation.

The Alameda, California-based company said the trial demonstrated that continuous fermentation can be integrated seamlessly at larger scales with robust, globally replicable performance.

Key results included a threefold increase in productivity, more than 50% reduction in projected costs of goods sold (COGS), and rapid adaptability powered by Pow.Bio’s machine learning and predictive control systems.

“ATV has been a reliable partner with a highly skilled team who have helped bring our technology to life at a larger scale,” said Shannon Hall, CEO & Co-founder of Pow.Bio. “This collaboration proves that our continuous fermentation platform delivers reliably at scales that matter with unmatched economic viability.”

The project leveraged Bühler’s pre-qualification and facility adaptation expertise to prepare ATV’s site for continuous trials, enabling a smooth transfer of Pow.Bio’s technology. According to Bühler’s Director of Innovation, Thierry Duvanel, the approach demonstrated that “today’s biomanufacturing lines can be made truly data-driven and self-optimizing – delivering higher yields, greater stability, and consistent performance at scale.”

Karima Zitouni, General Manager at ATV Technologies, said the collaboration pushed the company to “rethink what’s possible in fermentation”, combining continuous processing with intelligent optimization to achieve “results that far exceeded our expectations.”

Pow.Bio’s CapEx-light strategy enabled the existing facility to produce three times more product from minimal investment, underscoring the platform’s potential for retrofitting and rapid implementation across current biomanufacturing infrastructure.

With industrial-scale expansion now in development, the partners described the project as a crucial proof point for the future of continuous biomanufacturing. Pow.Bio plans to release further results and a case study in the coming weeks.