CFD Simulation, Process Optimization, Scale-Up & Validation
From lab bench (1L) to pilot (100L) and commercial production (10,000L+), BioFlo provides end-to-end fluid dynamics simulation, yield optimization, scale-up modeling, and digital twin validation.
Core Service Offerings
Simple, reliable, and scientifically rigorous engineering solutions designed for biopharma, fermentation, chemical processing, and OEM equipment manufacturers.
1. CFD Simulation Services
Computational Fluid Dynamics (CFD) simulation allows you to see inside your tanks, pipes, and bioreactors before spending money on fabrication or physical trials.
We model velocity profiles, mixing patterns, turbulence kinetic energy, and pressure drops to eliminate dead zones and ensure uniform liquid movement.
- ✓ Fluid flow & velocity streamlines analysis
- ✓ Gas-liquid multiphase flow & bubble dispersion
- ✓ Dead zone & stagnant volume elimination
- ✓ Shear stress mapping for fragile cells & microbes
2. Process & Yield Optimization
Maximize product yield and reduce batch cycle times by tuning critical hydrodynamic and biological parameters.
We calculate and optimize oxygen mass transfer rates (kLa), nutrient distribution, mixing homogeneity time (θ₉₅), and power consumption to lower your production cost per liter.
- ✓ Oxygen mass transfer rate (kLa) maximization
- ✓ Blend time (θ95) & homogeneity optimization
- ✓ Power consumption & energy efficiency tuning
- ✓ Feed port location & sparger design optimization
3. Scale-Up Engineering
Moving from a small 1L lab flask or 5L bench fermenter to a 1,000L or 10,000L commercial tank is where most bioprocesses fail due to poor mixing and oxygen starvation.
Our scale-up engineering establishes exact dimensional scaling, geometric ratios (H/D), impeller staging, and power-per-unit-volume (P/V) matching so your yield stays constant at commercial scale.
- ✓ 1L to 10,000L+ seamless scale-up protocols
- ✓ Multi-impeller staging (Rushton, pitched-blade, hydrofoil)
- ✓ Constant P/V, tip speed & kLa scaling criteria
- ✓ Troubleshooting batch yield drops & foaming issues
4. Validation & Digital Twins
Ensure your process and equipment meet stringent regulatory, quality by design (QbD), and cGMP standards.
We generate physics-backed 3D digital twins and detailed computational validation dossiers for technology transfer, equipment qualification (DQ/IQ/OQ), and investor due diligence.
- ✓ 3D in-silico Digital Twins of operating bioreactors
- ✓ Structural stress (FEA) & thermal jacket validation
- ✓ Tech-transfer dossiers & design qualification reports
- ✓ cGMP & QbD regulatory readiness support
How We Work With You
From first call to delivered engineering report, our process is fast, transparent, and hassle-free.
1. Initial Intake
Share your vessel dimensions, current problem (yield loss, foaming, dead zones), or target scale.
2. CFD & Physics Simulation
We build 3D fluid meshes and run high-performance simulations to pinpoint exact flow behavior.
3. Design Optimization
We refine impeller geometry, baffle placement, sparging rates, and RPM to achieve peak performance.
4. Final Report & CAD
Receive manufacturing-ready CAD drawings, simulation plots, and a clear executive summary for your team.
Have a Process or Tank to Simulate & Optimize?
Discuss your project specifications directly with our simulation and process engineers. Get an estimate and feasibility plan in 24 hours.