Danish industrial biotechnology startup Cellugy has successfully completed the first industrial-scale demonstration of its proprietary fermentation platform, scaling production 10x to 15,000 liters while consistently reproducing product quality and performance. Conducted in collaboration with Bio Base Europe Pilot Plant (BBEPP), the demonstration represents a major milestone in Cellugy’s transition from pilot-scale development to commercial manufacturing.
For customers, this achievement demonstrates that Cellugy’s manufacturing process can reliably deliver the same material characteristics at an industrial scale, a critical requirement for future commercial production and customer supply. By successfully reproducing these characteristics at 15,000 liters, Cellugy has significantly reduced scale-up risk and provided a stronger foundation for commercial partnerships and continued market adoption.
“Scaling production to 15,000 liters is more than an operational achievement. It is a commercial validation that enables deeper engagement with strategic customers and manufacturing partners. As brands accelerate their transition to more sustainable formulations, this milestone strengthens our position to bring EcoFLEXY to market as the next-generation multifunctional performance technology enabling superior suspension, enhanced sensory properties, and formulation innovation beyond traditional fossil-based rheology modifiers.”– Koen Paesmans, Chief Commercial Officer, Cellugy ApS
A critical step toward commercial production
Cellugy develops high-performance, bio-based functional ingredients through a proprietary microbial fermentation platform that produces tailored exopolysaccharides (EPS). These advanced materials deliver rheology, stabilization, sensory and bioactive functionalities while replacing petrochemical and microplastic-based materials without compromising performance.
EcoFLEXY Rheo, the first product developed from the platform, is a biodegradable rheology modifier for personal care applications, delivering excellent suspension, stability and sensory performance, including in challenging formulations. Beyond EcoFLEXY Rheo, the platform enables the development of new polymers for surfactant-rich and industrial applications, as well as bioactive variants for higher-value markets.
Built on a common fermentation backbone, the platform allows Cellugy to rapidly expand its product portfolio while leveraging the same scalable, capital-efficient manufacturing infrastructure. The successful scale-up to 15,000 liters further demonstrates the platform’s potential to support future commercial production and the development of additional product families.
The 15,000-litre demonstration was carried out at BBEPP’s facility in Belgium, using industrially relevant fermentation infrastructure and expertise to validate the robustness, reproducibility and industrial scalability of Cellugy’s fermentation platform.
“Scaling a fermentation process from 4 liters to 15,000 liters in just 16 months is a significant achievement. Across multiple scale-up stages, the BBEPP and Cellugy teams continuously adapted process parameters and implemented necessary scale-specific adjustments. This approach resulted in a robust and straightforward scale-up protocol, overcoming the challenges of working with a non-conventional product that yields a unique broth texture. Cellugy and BBEPP shared the common goal of bringing this technology closer to market. This scale-up story is proof that, with a well-thought-out scale-up plan, even the most unique fermentation processes can be run successfully at 15,000 litres scale.” – Hendrik Waegemani, Head of Business Operations, Bio Base Europe Pilot Plant
For Cellugy’s biotechnology scale-up expert, Alex Patist, PhD, the successful demonstration marks a significant step from technology validation to manufacturing at scale.
“A great example of what a disciplined, stepwise approach to scaling-up a bioprocess looks like. Cellugy’s collaboration with BBEPP to successfully bring the EcoFLEXY process to 15,000 L scale is a significant achievement, and a very different challenge from demonstrating the process at pilot scale. At this volume, consistency, reproducibility, and equipment transfer are truly put to the test. Reaching 15,000 litres is a major milestone and an important step toward commercial manufacturing. – Alex Patist, PhD, Biotechnology Scale-Up and Commercialization Expert
With the industrial-scale demonstration now completed, Cellugy has reached an important inflection point in its development. The successful replication of product quality at 15,000 liters demonstrates a scalable manufacturing platform capable of supporting future customer demand and expanding into additional product categories.
The company will build on the knowledge gained through the demonstration as it advances EcoFLEXY toward commercial production and broadens the application of its fermentation platform across the cosmetics, personal care, and other high-value markets.
CONTACT at CELLUGY:
Isabel Alvarez-Martos, CEO & Co-founder
+45 42610367 – isabel.martos@cellugy.com
About Cellugy
Cellugy is a biotech startup based in Søborg, Denmark, dedicated to developing natural and high-performing cellulose solutions to reduce the global impact of petrochemical pollution. Founded in 2018, Cellugy’s vision is a future where chemicals are bio-based, biodegradable, and produced using the principles of green chemistry. The company’s innovative platform technology has the potential to revolutionize many petrochemical-dependent industries, ultimately contributing to a healthier planet and a more sustainable future for everyone.
Cellugy has raised over €17M from a combination of VCs, private investors, and public funding. Thirteen different nationalities represent its diverse team of nineteen employees. Backed by more than twenty leading organizations that recognize the transformative potential of its technology, Cellugy is well-positioned to propel a new era of sustainable material science. For more information, visit www.cellugy.com.
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