Disclosure: This post is sponsored by Beckman Coulter Life Sciences and reflects their views, opinions, and insights.
Biomanufacturing is becoming a cornerstone of sustainable innovation, enabling industries to develop everything from biofuels and industrial materials to food and therapeutic ingredients by selecting, modifying, or reprogramming microorganisms, cells, or even plants.
Researchers in this field undergo the Design-Build-Test and Learn process (DBTL) under time-to-market constraints. For these iterations to be truly effective, they need to ensure reliability, reproducibility, and robust data tracking throughout the process, while keeping in mind the scale-up challenges.
We connected with Maria Savino, Global Segment Development Manager at Beckman Coulter Life Sciences to explore how automation, advanced data handling, and high-throughput tools are redefining biomanufacturing workflows, making them faster, more scalable, and environmentally conscious.
What are the stages involved in the biomanufacturing process, and how does Beckman accelerate the Design, Build, Test, Learn (DBTL) cycle to enhance production efficiency?
Biomanufacturing follows a structured path that includes organism selection, upstream development, validation, and scale-up. This process is significantly accelerated by high-throughput DBTL workflows, which improve the efficiency of each phase. Beckman Coulter Life Sciences supports researchers throughout this journey—from gene build to early scale-up.
We begin with tools like the Echo Acoustic Liquid Handler, which uses acoustics to dispense liquids without tips. It delivers drops as small as 2.5 or 25 nL from any well to any well, at speeds up to 700 drops per second. This enables rapid DNA assembly, completing tasks up to 93% faster than traditional methods and allowing for quick plasmid construction.
Next, the Biomek i-Series workstation paired with Beckman genomic reagents for plasmid extraction allows 9.6x more throughput before moving to the Echo Acoustic Liquid Handler for low-volume library construction and pooling. The Biomek platforms also handle steps such as cell transformation, culture, and plating. Finally, the BioLector XT Microbioreactor provides real-time monitoring of growth parameters, helping to identify and optimize the most promising candidates quickly.
Our modular automation can support discrete steps or fully integrated 24/7 workflows, shrinking DBTL cycles from weeks to days while ensuring data consistency and reliability.
How are organisms selected or genetically modified for biomanufacturing, and what technologies are used to optimize their traits for commercial product production?
Organism reprogramming and selection typically rely on directed evolution or genetic modification using tools like CRISPR. Beckman platforms support both approaches. For precise monoclonal selection, the CytoFLEX SRT Cell Sorter enables high-precision screening based on factors such as productivity, size, and stress response.
The BioLector XT Microbioreactor further supports high-throughput screening with real-time monitoring across up to 48 parallel experiments. This enables efficient trait optimization and tight data tracking throughout the DBTL cycle. Additionally, the Multisizer 4e Coulter Counter provides detailed cell sizing and particle analysis, critical for identifying top-performing clones during large-scale screening and optimization efforts.
How does integrating automation and data handling improve biomanufacturing processes?
Integrating automation and data handling in biomanufacturing enhances reproducibility, increases throughput, and ensures traceability across complex workflows. Beckman Coulter Life Sciences provides a fully integrated approach that combines instruments, software, and expert support. SAMI EX software automates scheduling and resource optimization across devices, ensuring smooth and efficient workflow execution.
Recognizing that every lab has unique needs, the Access Solutions Group (ASG) offers customized automation through deep workflow analysis. With experience integrating over 300 third-party devices from more than 60 manufacturers, ASG transforms standalone systems into fully integrated workflows—ranging from single-device setups to complete robotic systems—tailored to specific applications.
Additional features, like DeckOptix cameras on Biomek systems, offer live monitoring and error tracking to boost reliability. Together, these tools empower synthetic biology teams to complete DBTL cycles faster and with greater confidence.
What are the challenges faced when scaling up biomanufacturing processes from laboratory to industrial scale, and what strategies can be employed to mitigate these risks?
Scaling up—often referred to as the “Death Valley” of biomanufacturing—brings risks such as changes in behavior at scale, productivity loss, and contamination. Beckman technologies help mitigate these challenges throughout the process.
The BioLector XT Microbioreactor is key for pre-optimizing growth conditions. It provides control over individual pH, feeding strategies, gas concentration, temperature, and shaking speed. It also tracks key parameters like biomass, dissolved oxygen, and fluorescence in real time, significantly improving scale-up success rates.
When integrated with Biomek platforms, the BioLector XT Microbioreactor also helps optimize media to improve productivity in downstream processes. Additionally, expert support from our Field Application Scientists ensures process continuity and seamless integration across the entire scale-up journey.
How does biomanufacturing contribute to sustainability, and what strategies are being adopted to minimize environmental impact and reliance on non-renewable resources?
Biomanufacturing supports sustainability by replacing fossil-derived materials with biologically sourced alternatives. Beckman enhances this alignment with environmental goals through its innovative instruments and workflow solutions.
The Echo Acoustic Liquid Handler reduces plastic waste and lowers reagent volume consumption through tip-less acoustic dispensing. The BioLector XT Microbioreactor enhances strain optimization, reducing failed scale-ups and conserving resources. High-throughput platforms like the CytoFLEX Flow Cytometer and Biomek Workstation minimize waste while maximizing data-driven decision-making. These technologies support cleaner, faster, and more adaptable production pipelines aligned with circular bioeconomy strategies.
In your experience, having a broad overview of global biomanufacturing activities, what key factors would you identify as critical for achieving success in this field?
Success in biomanufacturing hinges on collaboration—bringing together scientists, engineers, and automation experts. Strong partnerships between industry, academia, and solution providers are critical to transforming innovation into scalable, real-world solutions.
More about Beckman Coulter Life Sciences
Beckman Coulter Life Sciences not only provides the hardware and software to power modern biomanufacturing, but they also offer the people and expertise to co-create optimized workflows tailored to your goals.
Whether you're building the next generation of sustainable materials or in the early steps of scaling up a breakthrough microbial process, the company’s holistic approach—from instrumentation to integration—drives faster, smarter, and greener biomanufacturing.
Discover how Beckman Coulter Life Sciences can help accelerate your biomanufacturing journey.
Learn about this year's Synthetic Biology: Engineering, Evolution, & Design (SEED) conference, and stay tuned for updates on the 2026 SEED conference taking place June 15-18 in Denver, CO.
Maria Savino
Maria Savino is Global Segment Development Manager at Beckman Coulter Life Sciences.
Disclosure: This post is sponsored by Beckman Coulter Life Sciences and reflects their views, opinions, and insights.