Biofactories: Sustainable Production of Biological Molecules for Industrial Applications

The dependence on fossil-based resources and the large volumes of raw materials required to obtain high-value ingredients for the food, cosmetics, and pharmaceutical industries make it essential to seek more sustainable alternatives. Industrial biotechnology is emerging as one of the key solutions, offering both sustainability and production efficiency. Within this field, biofactories are attracting increasing attention from industry players.

Why Biofactories Matter in Today’s Competitive Landscape

Biofactories refer to organisms that have the natural or engineered ability to produce biological molecules of industrial interest at high yields. These molecules may include plant growth regulators, pharmaceutical active ingredients, bioactive compounds for functional foods, cosmetic actives, biopreservatives, or biomaterials, among others.

Many of these biological molecules are currently produced from fossil sources (such as polymeric materials, surfactants, or other industrial substances) or require large amounts of raw materials for their extraction (as is the case with certain flavourings and bioactive compounds). Additionally, some are derived from sources that raise ethical or environmental concerns. In these scenarios, biofactory-based organisms provide a sustainable, cost-effective, and environmentally friendly alternative for producing key biological molecules.

In some cases, the goal is not merely to replace an existing molecule but to develop completely new functionalities—such as innovative pharmaceutical or cosmetic active ingredients produced through mammalian or plant cell cultures.

How Biofactories Work and Their Key Benefits

In most cases, the production platform involves microorganisms or cell cultures grown in bioreactors containing carefully designed nutrient media. Once the production process is complete, separation and purification steps are carried out to isolate the desired biological molecules under optimal conditions for their intended use.

The core of this process is the microorganism or cell line used as the biofactory. While certain microorganisms naturally produce specific molecules, in many cases, production levels are too low, or the molecule is not produced at all. Here, genetic engineering becomes essential to achieve efficient and sustainable production.

This process involves the use of specialised tools, known as “expression vectors” and “genetic parts”, which are used to genetically modify the biofactory organism. The quality and precision of these genetic tools largely determine the efficiency of both the development phase and the subsequent production process.

Once the target biological molecules are obtained through biofactories, it becomes essential to select purification and extraction processes that preserve the integrity of these compounds, especially when dealing with sensitive or bioactive substances. Among the most effective technologies in this context is supercritical CO₂ extraction, a versatile and environmentally friendly solution that enables the isolation and concentration of functional ingredients without the use of organic solvents, ensuring the preservation of the bioactive properties of molecules produced through biofactories.

This synergy between bioproduction and advanced separation technologies opens new possibilities for developing high-purity, sustainable ingredients for food, cosmetics, and pharmaceutical applications, facilitating the creation of innovative, high-value products.

Advanced Genetic Engineering Tools for Biofactories

Within the framework of initiatives funded by IVACE (Valencian Institute for Business Competitiveness) under its collaboration with AINIA to support industrial R&D activities, we are developing new genetic engineering tools to design genes for producing various proteins and even complete metabolic pathways. These advanced biofactory systems allow us to accelerate the development of viable, tailored solutions for different industrial needs.

From Microorganism to Final Product: Full-Process Development at AINIA

At AINIA, we offer complete process development—from the engineering of the microorganism to the production of the final product. Our expertise and specialised equipment cover every stage of the process, ensuring efficient and scalable results.

If you are seeking to enhance sustainability and efficiency in your operations, we invite you to contact us and explore the potential of biofactories for your business.