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Blog Post

July 13, 2026

Scaling Process Development Without Scaling Infrastructure: A Case Study

Scaling Process Development Without Scaling Infrastructure: A Case Study

How cloud-connected bioprocess development services are helping teams execute larger, more complex DOE studies. 

Design of Experiments (DOE) has become a cornerstone of modern upstream process development. By evaluating multiple process variables simultaneously, DOE enables scientists to optimize media, feeds, and operating conditions more efficiently than traditional one-factor-at-a-time experimentation.

Yet despite advances in experimental design, many process development teams still face the same challenge: execution.

As development programs grow in complexity, scientists need to generate more data, evaluate more variables, and make decisions faster than ever before. But running statistically powerful DOE studies requires significant bioreactor capacity, standardized execution, in-process analytics, and the resources to manage dozens of experiments in parallel.

Moving Beyond Traditional Laboratory Constraints

Expanding process development doesn't always require building more laboratory space or purchasing additional equipment. Increasingly, organizations are turning to outsourced bioprocess development partners to extend their internal capabilities, execute complex studies more efficiently, and accelerate development timelines while maintaining scientific rigor, reproducibility, and data quality.

Nexxys™ is Culture Biosciences' fully managed bioprocess development service, built on cloud-connected bioreactors powered by Console™. Console provides real-time visibility into every experiment and includes advanced AI capabilities, such as ChatDoE™, helping scientists design experiments, analyze data, and accelerate decision-making throughout process development.

The result is faster experimental execution, greater confidence in process decisions, and more time for scientists to focus on innovation rather than laboratory operations.

From Theory to Practice

A recent process development project with MilliporeSigma demonstrates how this approach can help accelerate complex DOE execution.

The Nexxys™ team executed five full-factorial DOE studies across multiple CHOZN® cell lines using Culture Biosciences' cloud-connected bioreator platform. The project enabled statistically robust evaluation of multiple media and feed combinations, identified significant improvements in recombinant protein titer for multiple cell lines, and successfully confirmed the optimized conditions at the 3 L bench scale.

Beyond the experimental results, the project highlights a broader shift in how organizations approach process development. Rather than allowing laboratory capacity to dictate the scope of experimentation, teams can leverage cloud-connected bioprocess services to execute larger studies, generate higher-quality datasets, and accelerate scientific decision-making.

Learn More

Download the full white paper to explore the experimental design, statistical analysis, and scale-up confirmation from the MilliporeSigma project. Then, speak to a bioprocess expert to learn how Nexxys can help accelerate your next process development program.