Automated cultivation of biomass
Algae are small climate savers. Even in their natural state they are extremely efficient photosynthesizers and absorb ten times more carbon dioxide (CO₂) than land plants. In bioreactors equipped with appropriate sensors, control technology and automation, the efficiency of algae can be increased to a hundred times that of land plants. This shows that they have a significant potential for a climate-neutral circular economy. With the PhotoBionicCell research project Festo demonstrates a potential approach for the industrial biologisation of tomorrow.
Our world is changing to an unprecedented degree. World population is growing and the consequences of climate change are already being felt. We will have a liveable future only if people, animals and the plant world live in harmony. This is why at Festo we consider the bioeconomy the economic system of the future. “Our aim is to make a significant contribution to improving the quality of life of today's and future generations by the large-scale cultivation of biomass using our automatic technology,” says Dr. Elias Knubben, Vice President Corporate Research and Innovation.
Biology as inspiration
The bionics team is now also looking more closely at photosynthesis. At Hannover Messe 2022, Festo demonstrated the PhotoBionicCell project as an example of industrial biologisation. With the innovative photobioreactor, algae can be automatically cultivated and their growth controlled. The algae cells, through photosynthesis in their chloroplasts, convert sunlight, carbon dioxide and water into oxygen and chemical energy carriers or organic recyclable materials. With automation technology from Festo, e.g. for optimal gassing and mixing, algae can absorb one hundred times more carbon dioxide than land plants such as trees or maize.
Biological recyclables for climate-neutral end products
As part of their metabolic processes, algae produce fatty acids, colour pigments and surfactants. These can be used as the raw materials for the production of medicines, food, plastics or cosmetics. Unlike petroleum-based products, the biobased end products can usually be biodegraded and, in keeping with an overall circular economy, always recycled in a climate-neutral manner. For example, the production of a shampoo container requires about one litre of petroleum. If the shampoo bottle is incinerated after use, it releases an additional three kilogrammes of CO₂ and thus has a negative CO₂ balance. If bio-plastic based on algae is used instead, three kilogrammes of CO₂ are absorbed, which are released again when the bottle is disposed of. Thus, the cycle is in balance.
Efficient photosynthesis in the high-tech bioreactor
During their work on the PhotoBionicCell, the researchers focused on the cultivation of the blue-green algae Synechocystis. They produce colour pigments, omega-3 fatty acids and polyhydroxybutyrate (PHB). When this PHB has been extracted, it can be processed by adding other substances, and used for example in 3D printing.
A major challenge for bioreactors is how to precisely determine the volume of biomass. Festo relies on a quantum technology sensor supplied by the start-up Q.ANT to do this. It returns accurate information on the growth of the organisms in real time. Using microfluidics such as pumps to precisely control minute volumes of liquid, the algae are automatically and continuously pumped in the quantum sensor. The quantum sensor is able to optically analyse individual cells so that the amount of biomass can be precisely determined. In addition, it uses artificial intelligence (AI) to examine the cells for their vitality. Only then is it possible to anticipate and react to process events and to intervene in a controlled way.
Software solutions for a digitalised laboratory
Many laboratory analyses have been done manually up to now. This is slow and can result in errors. The automation of such laboratory systems in the future will enable all required data to be read directly and in real-time.
To achieve this, in-house developed software is used for the PhotoBionicCell. The dashboard allows multiple photobioreactors to be displayed with the current data situation and live images. Changes to parameters and the corresponding evaluations can be made around the clock and even remotely. Users can thus respond to changes in the bioreactor at any time and, for example, start harvesting the product at the optimum time.
Artificial Intelligence for further optimisation
The developers at Festo are also using AI to evaluate the data. This allows the bioreactor to be optimised for propagation of the algae cultures or to maintain specified growth parameters with minimal energy input.
About Festo
Festo is a leading international supplier of automation technology with a turnover in 2023 of around €3.65 billion. Festo employs over 20,600 people worldwide and is a proven innovator and problem solver in pneumatic and electrical automation, where it is the performance leader. Festo offers around 33,000 pneumatic and electric products in hundreds of thousands of variants for factory and process automation technology, many of which can be tailored to specific customer needs. Sustainability, reducing its CO2 footprint, digital learning, innovation, performance and speed are the key drivers for the company's future. Festo GB operates as a carbon neutral organisation and uses the PAS 2060 standard externally audited by NQA to validate this claim to customers, employees and other stakeholders.
Festo Industrial Automation's innovative strength is demonstrated through the launch of around 100 new products every year. The company invests over 7% of its turnover in R&D, resulting in over 2,600 patents held worldwide. For more information about the company's products and UK / Irish services, please visit: www.festo.com/gb and www.festo.com/ie
Festo and Industry 4.0 - Festo has engaged with the Industry 4.0 initiative from its inception: as a user, manufacturer and trainer. As a member of the steering group, the company has taken an active role in defining the core standards such as the RAMI model and the Administration Shell. Festo Didactic has installed Industry 4.0 Cyber-Physical Factory training hardware systems in many leading universities and training centres. It also provides Industry 4.0 training courses for change managers and practical workshops for employees. Industry 4.0 technologies such as OPC-UA communications are embedded in the latest generation products. For more information, go to www.festo.com/digitalisation
Festo Didactic training delivers training for industry – by industry. Combining Festo's industrial heritage with its future-focused manufacturing and engineering expertise to deliver courses for greater productivity and competitiveness. Offering a wide range of open courses, structured development programmes and tailor-made, customer-specific projects on technology and Industry 4.0 and the industry-leading online training suite, Festo LX. Festo also provides state-of-the-art training equipment solutions for industrial companies and educational institutions around the world. Festo Didactic has around 56,000 education customers worldwide. More information on Festo training and consulting services can be found at: www.festo.com/didactic
Festo Bionic Learning Network encapsulates the innovative nature of Festo, raising awareness and attracting talent to the company. Exploring the links between nature and technology opens new areas of innovation and demonstrates complex ideas in a stimulating and enjoyable way. Festo works with an alliance of internal R&D, external educational establishments and specialist companies to advance bionic solutions for automation applications of the future. The objective is to benefit from bionics as a source of inspiration and to realise these in industrial automation. For more information about Festo's Bionic Learning Network, please visit: www.festo.com/bionics
