ProtPilot

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Project Details

Research Name

ProtPilot – Pilot-scale protein bioproduction

Research TYPE

Industrial Scale-Up & Process Innovation

Delivery Mode

Pilot-to-Semi-Industrial Technology Transfer

Location

Braga, Portugal

Pilot-scale protein bioproduction

Since its founding in 2016, Solfarcos has been committed to pioneering biotechnological advancements focused on the cosmetic and pharmaceutical industries.

The ProtPilot project emerged from Solfarcos’ strategic need to consolidate and expand its in-house capabilities for the biotechnological production of proteins and peptides for the cosmetics sector. As demand for high-performance biotechnology-derived ingredients continues to grow, it became essential to establish a dedicated production unit capable of increasing operational efficiency, optimizing processes, and delivering greater value to clients and partners.

As implemented, the project enabled the completion of infrastructure adaptations for a recombinant protein production facility, the acquisition of state-of-the-art equipment for protein fermentation, expression, and purification, the execution of critical research and development activities to support scale-up and process optimization, and the recruitment and retention of a highly specialized technical team.

The funding obtained played a catalytic role in strengthening Solfarcos’ ability to meet the growing demand for niche biotechnology products, expand its international presence, and reinforce its position as a leading company in biotechnology applied to the cosmetics industry. The most significant milestone demonstrating the project’s success was the launch of K18’s AirWash™ Dry Shampoo at the end of the first quarter of 2024, featuring Solfarcos’ OBProTec protein produced at the newly established manufacturing facility. In addition to becoming the first cosmetic product on the market to incorporate a recombinant protein, it became Sephora’s best-selling product during its first week of commercialization, validating both the technology and the company’s strategic positioning within the global cosmetic biotechnology market.

With technology readiness levels (TRLs) advancing from TRL 1–4 to TRL 6–9 across its various objectives, ProtPilot has established itself as a transformative project for Solfarcos, strengthening its position as a reference in cosmetic biotechnology and enabling the company to meet the growing demand for innovative, sustainable, and high-performance solutions. The project focused primarily on process innovation rather than the development of new end products. The work plan was structured around four interconnected and complementary objectives:

Development of a Semi-Industrial Protein Production and Purification Process (TRL 4 → 8)

This objective focused on optimizing fermentation processes capable of achieving yields between 0.5 and 5 g/L, using flexible production systems with different microorganisms (bacteria or yeast), production modes (intracellular or extracellular), and operational approaches (batch or fed-batch). The application of statistical process development methodologies accelerated optimization efforts, a critical factor given the product launch timelines required by clients. Yield improvements are essential to ensuring competitive production costs in a sector where recombinant protein manufacturing has traditionally been significantly more expensive, particularly within the biomedical industry.

Pilot Bioproduction Platform for Multiple Proteins (TRL 3 → 9)

This objective required close collaboration with a specialized engineering team responsible for designing and installing pilot-scale manufacturing equipment. Success was measured by comparing productivity levels between laboratory-scale processes and pilot/semi-industrial production operations.

Modular Pilot Protein Purification System (TRL 3 → 9)

This objective focused on scaling laboratory purification processes through the implementation of separation, clarification, and filtration modules capable of operating at pilot and semi-industrial scales.

Waste Management and Resource Recovery (Water and Biomass) (TRL 1 → 6)

This objective aimed to reduce water consumption and promote waste recirculation without compromising product quality or safety. Activities ranged from process modifications, such as replacing dialysis with tangential flow filtration, to equipment redesign initiatives, including the implementation of recirculating cooling systems. This represented the highest-risk objective due to its dependence on the stability and maturity of the other process developments.

Funded by

The ProtPilot operation was funded by Portugal 2030 and the European Union. European Funds Closer to You.