Photobioreactors for phototrophic process development and tubular scale-up

Built for comparative screening and early process decisions

xCUBIO phar bubble is built for comparative screening, parameter optimization and reproducible early-stage process development with phototrophic microorganisms.

Instead of running isolated test setups, users can compare strains, media compositions and operating strategies under defined parallel conditions and generate results that are more meaningful for the next development step.

From single systems to up to 24 independent vessels

The xCUBIO phar bubble family covers compact single and twin systems as well as scalable multi-vessel platforms with up to 24 independent vessels.

In its larger architecture, the xCUBIO multi controller can operate up to six supply towers and up to 24 bubble-column vessels within one integrated system environment.

This allows users to start with a smaller setup and expand step by step into a powerful parallel development platform in which each individual bioreactor can be monitored and controlled separately.

Defined vessel conditions for meaningful parallel experiments

Meaningful parallel experiments depend on more than vessel count. The xCUBIO phar bubble platform combines autoclavable borosilicate glass bubble columns with defined temperature conditioning, efficient light use and reproducible internal circulation.

The vessel design uses a double-walled lower section for thermal control and a single-walled upper section for improved light utilization, while coarse-bubble aeration and dedicated magnetic stirring support stable suspension and comparable process conditions across vessels.

Each reactor can be equipped with its own illumination unit with four independently controllable wavelengths, allowing spectrum and intensity to be adjusted specifically for each experiment. This supports flexible optimization for different strains, media compositions and cultivation strategies without losing the comparability of a parallel platform.

xCUBIO automation for serious phototrophic development

What sets the platform apart is not only the reactor hardware, but the automation behind it. xCUBIO provides a central environment for process control, visualization, calibration, alarms, trend display, data export and recipe-based operation.

Profile functions and the built-in sequence editor support day-night strategies, dynamic illumination profiles, gas switching, timed additions and more advanced process routines without external software.

For laboratories that take phototrophic process development seriously, this matters. It means that parallel experiments can be planned, executed, documented and expanded within one structured automation environment instead of being held together by disconnected lab components.

Built for scale-up-relevant tubular process development

The xCUBIO phar tubular is designed for laboratory-scale cultivation and process development under conditions that are already much more relevant for later tubular scale-up.

By integrating key functional elements of larger tubular photobioreactors – especially the borosilicate glass tube loop and continuous recirculation – it creates a more representative process environment than conventional small-scale phototrophic systems.

This helps generate laboratory data with improved relevance for transfer to larger tubular reactor concepts.

Glass spiral and central process vessel in one integrated unit

The cultivation unit combines a tubular glass spiral as the main illuminated circulation section with a central double-walled process vessel that serves as degassing, sensor and process interface vessel.

The glass spiral forms a representative tubular reactor section for development work, while the central vessel provides the practical process functions needed for sparging, sensor integration, media addition and controlled operation.

Together, these two elements create a compact laboratory system with a much more realistic tubular reactor logic.

Illumination, recirculation and process control as one concept

The xCUBIO phar tubular is not just a small tubular reactor with light around it. It is built as an integrated development system in which illumination, recirculation, temperature control and process handling work together as one coherent cultivation concept.

This is especially important in phototrophic process development, where reactor performance is shaped not by one single feature, but by the interaction of light exposure, tubular circulation, gas exchange and controlled process conditions.

By combining these elements within one laboratory-scale platform, the system supports more meaningful development work for later tubular reactor transfer.

A bridge from screening to pilot-scale tubular systems

Parallel screening systems are highly useful for comparing strains, conditions and basic process directions. But when the next question is how a process behaves in a genuinely tubular reactor concept, a more representative development platform becomes necessary.

This is exactly the role of the xCUBIO phar tubular. It creates a practical intermediate step between early-stage phototrophic screening and larger pilot-scale tubular systems.

As a result, it helps reduce the gap between initial feasibility work and later scale-up decisions by allowing tubular process behaviour to be assessed earlier and under more relevant development conditions.

Built for pilot-scale tubular process development and small production lots

The xCUBIO phar in-situ is designed as a premium pilot-scale tubular photobioreactor platform for the cultivation and process development of phototrophic microorganisms under controlled and highly reproducible conditions.

By combining the key functional principles of larger tubular photobioreactors in a laboratory-accessible format, it creates a process environment with much clearer relevance for later scale-up than small bench-scale photobioreactors or very small illuminated lab systems.

Modular illuminated volumes from compact pilot to small production setups

The platform is built around a modular concept with one illuminated cultivation module as standard and an optional second module for extended operation.

In the 30 l / 55 l execution, this expands the working volume e.g. from approximately 30 l to approximately 55 l.

In the larger 100 l / 175 l execution, the system grows from approximately 100 l to approximately 175 l while maintaining the same reactor geometry, hydraulic principle and overall process logic. This allows one platform to cover different development stages, from compact pilot studies to larger cultivation campaigns with up to 500 L.

Central process vessel and defined tubular recirculation

At the center of the reactor concept is a dedicated process and degassing vessel that forms the functional core of the system.

It provides the defined location for degassing, gas introduction, sensor integration, media addition, sampling and harvesting, while the tubular cultivation modules form the main illuminated production zone. Culture circulation is driven by a dedicated external pump, creating continuous recirculation through the tubular modules and the central vessel.

This separation of functions is a characteristic feature of advanced tubular photobioreactor design and supports reproducible hydraulic conditions, reliable suspension of the culture and process investigation under flow conditions that are already highly relevant for scale-up.

From controlled pilot operation to integrated SIP capability

The xCUBIO phar in-situ goes beyond the level of a classical research photobioreactor. Depending on the execution, the platform can be configured for chemical cleaning and sanitization or as a fully steam-sterilizable in-situ system.

In the larger pilot-scale execution, this includes an integrated tempering concept designed for controlled cultivation as well as steam-sterilizable operation, making the system particularly attractive for applications with increased demands on sterility, process robustness and regulated operation.

Together with flexible illumination concepts and premium xCUBIO automation, this creates a high-end pilot platform for advanced phototrophic process development.

Engineered for the step beyond research and pilot development

Large tubular photobioreactor systems are not simply scaled-up laboratory units. They require a different level of engineering, layout planning and process integration.

bbi-biotech supports this step with project-specific tubular systems designed for pilot operation, scale-up work and production-oriented phototrophic processes in larger operating environments.

Modular tubular layouts for greenhouse and outdoor cultivation

Depending on project requirements, larger systems can be designed as modular tubular layouts for greenhouse or outdoor operation.

This allows reactor geometry, footprint, accessibility and operational integration to be adapted to the cultivation strategy and the available site conditions, rather than forcing the project into a rigid standard format.

Project-specific system design for production operation

In this scale range, the focus shifts from experimental flexibility to robust and production-oriented system design.

Important factors include hydraulic layout, recirculation concept, component quality, cleanability, service access and the selection of durable industrial-grade components for long-term operation.

From process transfer to pilot and production planning

The value of larger tubular systems does not begin with fabrication alone.

bbi-biotech can support the transfer from earlier tubular development stages into pilot and production planning by helping to define suitable system concepts, operating logic and project-specific requirements for larger-scale implementation.

Illumination concepts built around the phototrophic process

In phototrophic cultivation, illumination is not a secondary feature, but one of the central process variables. With xCUBIO phar the illumination concept can be configured with much greater precision.

• Standard LED packages available for defined and reproducible baseline configurations
• Customized LED concepts with application-specific wavelengths
• Wavelength customization possible beyond standard algae ranges, including UV or IR
• Separately controllable light channels with adjustable spectral composition and intensity
• Fluorescent tube lamp systems also possible

CO₂ supply and monitoring for phototrophic processes

In algae cultivation, CO₂ supply is a central process function rather than a simple gas add-on. xCUBIO photobioreactors can be configured for more deliberate carbon supply and CO₂-related process monitoring.

• Precise CO₂ supply via mass flow controllers
• Gas-supply concepts can be adapted to the process and system architecture
• Multiple CO₂ injection points possible in larger system concepts
• CO₂ monitoring in the exhaust gas, for example with BlueSens sensors
• Inline CO₂ probes, including solutions from Hamilton or Mettler-Toledo

Optical density options for deeper process understanding

For many algae processes, optical density is one of the most informative additional parameters for understanding biomass development and using culture behaviour more actively in process decisions.

• Optical-density solutions can be integrated depending on process concept and instrumentation strategy
• Solutions from suppliers such as Optek, Hamilton or other manufacturers
• Useful for harvest, fed-batch strategies and other biomass-related operating logic

Flexible system architecture for changing development needs

Not every phototrophic project needs the maximum configuration. xCUBIO photobioreactors are built around a toolbox-like architecture that helps match technical depth more sensibly to project scope and budget.

• Toolbox-like system architecture instead of one rigid fixed package
• Easier to define a sensible balance between required features and investment level
• More compact starting configurations possible where appropriate
• Further functions and extensions can be added later as requirements grow