AMSilk scales up innovative silk proteins

Biomaterials inspired by spider silk

AMSilk is a biotechnology company that produces high-quality silk proteins through precision fermentation. The company uses these proteins to develop innovative biomaterials inspired by spider silk. Spider silk combines exceptional strength with flexibility and biocompatibility. According to Philipp Hecker, Development Project Manager at AMSilk, this makes it one of nature’s most versatile materials.

AMSilk’s silk proteins are designed to help industries transition to high-performance, bio-based alternatives without compromising functionality or performance.

At the momen the company focuses primarily on two application areas: yarns for textile applications and personal care solutions.

The challenge of scaling up

Scaling up a biotechnological process from laboratory to industrial scale is both complex and costly. A process that works well in the laboratory does not automatically produce the same results on a larger scale. This challenge is particularly significant for AMSilk because silk proteins have unique properties and therefore require a specialized production process.

During the fermentation step, for example, heterogeneities may develop within the reactor. This means that process conditions are not exactly the same throughout the reactor, which can affect the reproducibility, stability, and ultimate quality of the product.

One of AMSilk’s main challenges was therefore to develop and transfer a process that performs consistently from laboratory scale through to industrial production. A well-structured scale-up strategy involving the right partners was essential. It enables critical process requirements to be identified at an early stage, reduces technical risks, and helps prevent unexpected issues during full-scale production.

Drying as the final processing step

Bodec became involved in drying the protein suspension through a mutual scale-up partner. This step is critical to ensuring the quality and stability of the final product.

In a process like this, we look beyond simply removing moisture. We want to understand how the product behaves during drying, which conditions the protein can withstand, and which settings are required to achieve stable and reproducible results.

Throughout the project, we worked closely with AMSilk and exchanged extensive technical knowledge. Together, we gained a better understanding of the drying behaviour and stability of the silk proteins. This gave AMSilk greater clarity about the requirements this final processing step must meet during further scale-up. The trials also provided the company with sufficient product to continue developing both its product and its process.

Flexibility throughout the development process

Pilot trials regularly produce new insights. This requires both technical expertise and flexibility. Throughout the project, we were able to respond quickly whenever plans changed or additional tests were required.

Philipp Hecker of AMSilk identifies this combination of expertise, flexibility, and reliable results as one of Bodec’s key strengths: “Bodec has become a key partner in our scale-up portfolio, providing valuable expertise, flexibility and reliable drying results.” — Philipp Hecker, AMSilk

Reliable drying results and greater process knowledge

The collaboration has provided AMSilk with reliable drying results and increased knowledge of:

• the drying behaviour of the protein suspension;
• the stability of the silk proteins;
• the critical requirements of the drying process;
• the appropriate process conditions for further scale-up

Pilot facilities as a bridge to industrial production

Pilot facilities provide a vital bridge between laboratory research and commercial production. At pilot scale, it becomes clear whether a theoretical process can also be implemented practically and reproducibly. Scale-related effects can be investigated before major investments are made in full-scale production.

Pilot trials therefore reduce technical and financial risks and help prevent costly surprises during industrial production.