Continuous improvement is the key to success
Research and development
Only innovative companies can be successful in the long term - to fulfil this premise, research & development has always been a high priority at Lactosan. More than 15% of Lactosan's employees work in R&D. Micro- and molecular biological research groups are working in-house on the isolation of new strains and the further development of characterisation and identification methods. Our research groups in process technology and in the pilot plant contribute to the continuous improvement of our processes and support our customers in process development.
Microbiological laboratory
From isolating new strains, characterising them and studying their growth, to developing methods, the microbiological laboratory is constantly working on new insights. Rapid identification by PCR or whole genome sequencing are standard procedures after isolation.
DNA-Laboratory
For many of the strains stored at Lactosan, a DNA profile is created. Therefore, the identity of the strain in each production batch can be compared if necessary. Special primers are used to differentiate or unambiguously identify individual strains by sequencing. Special molecular biology services for customer strains (e.g. cloning) are also available on request.
Process technology laboratory
In the process technology laboratory, basic test series are carried out on the fundamental feasibility of processes. If required the processes can be optimised up to model production. In addition to conducting initial growth tests in shake flasks, the process technology laboratory is responsible for the complete analyses for the pilot plant. The state-of-the-art laboratory, which has its own media preparation, sample preparation and clean room with sterile workbenches for microbiological analysis, is also used to screen new strains with improved properties. In addition, chemical and microbiological analyses are carried out to answer customer-specific questions.
Enzyme analysis
The activity of all biotech batches is also determined in the process technology laboratory. Thanks to many years of experience, process steps can be quickly assessed here. This contributes significantly to process optimisation.
Special hygiene laboratory
The laboratory for special hygiene analyses deals with product quality control and incoming goods analyses. All parameters relevant to the food industry are analysed here. The laboratory is an essential part of release analyses and batch evaluation.
Pilot facility
The pilot plant fully replicates the Lactosan production lines (fermentation, separation, ultrafiltration, homogenisation, freeze-drying, fluid bed coating). Experience shows that everything developed in the pilot plant can be successfully implemented in large scale production. The pilot plant team develops a suitable production process for each strain provided by the customer. Working closely with our clients, all requests for raw materials and processes can be met. Wherever possible, standard raw materials, allergen-free media and easily transferable processes are used. As the plant is identical in all details to the production plant, the process can be easily scaled up. The pilot plant consists of three different fermentors and is equipped to mirror the production plant. The fermentation process is controlled by a process control system. The flexibility of the plant allows the influence of any parameter change on the process yield to be perfectly visualised. The plant is equipped with a CIP station and the fermentor and separator are steam-sterilised. The plant also includes a homogeniser and an ultrafiltration system. The concentrate can be dried by freeze-drying or spray drying.
