Fermentation is at the heart of many life-saving medicines. But when it comes to large-scale production, it’s one of the most unpredictable and complex processes in pharmaceutical manufacturing. At TAPI, we’ve taken a bold step toward solving this challenge—by combining data science, automation, and our deep process expertise to revolutionize how we manage substrate feeding in fermentation.
The Challenge: Complexity in Every Drop
As a global leader in active pharmaceutical ingredient (API) production, TAPI has a long-standing tradition of excellence in fermentation. Our largest fermentation site, based in Hungary, handles some of the most technically demanding production processes. These processes involve living organisms, over 200 hours of process time, and highly sensitive multi-variable conditions—all of which can lead to unpredictable yields and inefficiencies.
One of the biggest variables? Substrate concentration. It needs to be maintained within an extremely narrow range throughout the entire process, which is no easy task with such complexity in play.
The Solution: Smarter, Safer, and More Sustainable
To meet this challenge head-on, we partnered with a specialist in process control to develop and implement an automated substrate feeding strategy. The result: a cutting-edge system powered by big data analytics, real-time prediction (via a “soft sensor”), and continuous concentration control.
Key highlights include:
- Real-time control: The system calculates and adjusts the substrate dosage rate automatically, removing the need for manual sampling and reactive adjustments.
- AI-driven prediction: A soft sensor uses production data to predict substrate levels, enabling proactive decision-making.
- Seamless integration: The algorithm was designed to fit into existing systems without disrupting ongoing operations.
This wasn’t just a theoretical exercise—the system is live and delivering results.
The Impact: Greater Efficiency, Lower Carbon Footprint
Since implementing this control strategy, we’ve seen over a 15% increase in productivity, while simultaneously reducing our carbon footprint. By keeping substrate levels consistently optimal, the system minimizes fluctuations and improves reproducibility—two major pain points in any fermentation process.
And the best part? This approach is scalable. The same control model can be tailored and applied to other fermentation processes across our sites, unlocking even broader improvements.
Looking Ahead: A New Standard in Bioprocess Control
What sets this development apart is not only the technology—but the mindset behind it. We’ve shown that internal know-how, combined with external collaboration and smart data use, can lead to real operational transformation. With this innovation, TAPI is setting a new benchmark for how fermentation can be controlled: more precise, more consistent, and more sustainable.
This is just one example of how we’re advancing health from the core—by optimizing the very processes that make modern medicine possible.
