The Applikon BioPilot in Detail.

The Applikon BioPilot is a high-performance stainless-steel bioreactor system built for pilot-scale bioprocesses — the bridge between bench-scale development and full GMP manufacturing. Designed for simple, reliable control across long campaign durations, the BioPilot delivers reproducible results at every stage of scale-up, from media optimization and process refinement through to clinical and small-scale commercial batches under cGMP conditions. It supports microbial fermentation and mammalian cell culture across Batch, Fed-Batch, Perfusion and Continuous modes, in dedicated cell-culture and microbial vessel geometries.

BioPilot pedigree — built by Applikon for cGMP-ready scale-up.

The BioPilot is engineered by Applikon, a leading stainless-steel fermenter manufacturer with decades of experience designing bioreactor systems for the global biopharmaceutical industry. Every BioPilot is built to the latest hygienic processing standards with a cGMP-compliant design and full documentation — simplifying validation from day one. What sets it apart is a consistent scale-up design that runs seamlessly from bench through pilot to full production, a compact footprint that fits a pilot suite without sacrificing performance, and a fully modular architecture that lets you configure the system precisely to your process needs.

Easy operation with professional process control.

The BioPilot is built on Applikon’s modular architecture and configured with a wide range of standard add-on packs — including pressure control, weight control, feed control, biomass sensors and perfusion systems — letting you tailor the system precisely to your application. All vessels feature an electropolished interior surface finish of Ra ≤ 0.4 µm, minimising biofilm adhesion and simplifying cleaning and sterilisation across long-running campaigns. Operating parameters cover up to 2.5 bar pressure and 150 °C sterilisation temperature, with full SIP/CIP capability, water cooling and water/steam heating built in.

The BioPilot integrates with the Applikon ez2Control platform and Lucullus PIMS process management software for advanced data acquisition, recipe management and audit-trail-ready records. The system accepts sensors from AppliSens, Hamilton, Mettler Toledo, BlueSens and ABER sensor families — covering pH, dissolved oxygen, temperature, biomass, off-gas analysis and more. Sampling runs through an optional re-sterilisable sample system in a DN25 port in the lower side wall, with a re-sterilisable bottom-mounted bellows drain for harvest — both meeting the documentation and cleanliness standards required for GMP-ready processes.

Available BioPilot Volumes:

The BioPilot is available in a range of total volumes to suit your pilot-scale requirements. Working volumes range from 7.5 L to 200 L across all configurations.

Cell-culture geometries (1 : 1 aspect ratio)

1 BioPilot 30 L — working volume 7.5–20 L (1.5 : 1 aspect)
2 BioPilot 60 L — working volume 10–40 L (1.5 : 1 aspect)
3 BioPilot 130 L — working volume 28–100 L (1.5 : 1 aspect)

Microbial geometries (2.2 : 1 aspect ratio)

1 BioPilot 40 L — working volume 7.5–30 L (3: 1 aspect)
2 BioPilot 70 L — working volume 10–50 L (3: 1 aspect)
3 BioPilot 140 L — working volume 20–100 L (3: 1 aspect)
4 BioPilot 270 L — working volume 30–200 L (3: 1 aspect)

All BioPilot vessels are available with full Applikon controller integration and IQ/OQ/PQ documentation for cGMP environments. Talk to our Recherswil team to spec the right configuration for your bioprocess.

Attributes	Applikon BioPilot Stainless Steel Bioreactor 30L Cell Culture	Applikon BioPilot Stainless Steel Bioreactor 40L Microbial	Applikon BioPilot Stainless Steel Bioreactor 60L Cell Culture	Applikon BioPilot Stainless Steel Bioreactor 70L Microbial	Applikon BioPilot Stainless Steel Bioreactor 130L Cell Culture	Applikon BioPilot Stainless Steel Bioreactor 140L Microbial	Applikon BioPilot Stainless Steel Bioreactor 270L Microbial
L1 – Core Physical & Construction
Volume	30 L	40 L	60 L	70 L	130 L	140 L	270 L
Working volume range	7.5 – 20 L	7.5 – 30 L	10 – 40 L	10 – 50 L	28 – 100 L	20 – 100 L	30 – 200 L
Cell Type	Cell Culture	Microbial	Cell Culture	Microbial	Cell Culture	Microbial	Microbial
Footprint	1600 x 1000 x 1850 mm	1600 x 1000 x 1850 mm	1600 x 1000 x 1850 mm	1600 x 1000 x 1850 mm	1600 x 1000 x 1850 mm	1600 x 1000 x 2500 mm	2000 x 1200 x 3000 mm
Aspect ratio working volume	1 : 1	2.2 : 1	1 : 1	2.2 : 1	1 : 1	2.2 : 1	2.2 : 1
Aspect ratio total volume	1.5 : 1	3 : 1	1.5 : 1	3 : 1	1.5 : 1	3 : 1	3 : 1
Compatible motor types	Brushless Motor M14 / M33	Brushless Motor M33	Brushless Motor M14 / M33	ESA6 / M130	Brushless Motor M14 / M33	ESA6 / M130	Brushless Motor M133
Impeller types	Marine (Rushton)	Rushton	Marine (Rushton)	Rushton	Marine (Rushton)	Rushton	Marine / Rushton
L2 – System Properties & Process Parameters
Agitation / mixing speed (rpm)	0 – 260 rpm	0 – 750 rpm / 0 – 2000 rpm	0 – 260 rpm	0 – 750 rpm / 0 – 850 rpm	0 – 100 rpm	0 – 650 rpm / 0 – 800 rpm	0 – 535 rpm / 0 – 650 rpm
Motor torque	0.92 Nm / 2.43 Nm	5.9 Nm / 9.5 Nm	0.92 Nm / 2.43 Nm	5.9 Nm / 9.5 Nm	0.92 Nm / 2.43 Nm	26 Nm / 28.6 Nm	26 Nm / 50.1 Nm
Max Power (W)	360	485 – 2000	360	485 – 2000	360	2000 – 4500	2000 – 3500
Impeller Power no. Np	3	3 x 6	3	3 x 6	3	3 x 6	6
Max tip speed (m/s)	3.3 / 2.0	3.3 / 3.9	2.0	3.6	1.2	4.4	4.5

L1 – Core Physical & Construction

Technology Platform	Multi-Use
Wall Type	Jacketed
Material	Stainless Steel
Autoclavable	Yes
Max operating temperature	150 °C
SIP / CIP capability	Yes
Max sterilization temperature	150 °C
Max operating pressure	2.5 bar
Drive system	Magnetically coupled /Optional mechanical seal
Gas sparger types	Porous sparger / L-Sparger / Ring-type sparger
Cooling method	Water
Heating method	Water / Steam heating

L3 – Functional & System Capabilities

Sampling port	Optional re-sterilizable sample system in DN25 port in lower side wall
Harvest port	Re-sterilizable bottom mounted bellows drain
Geometric similarity maintained	Yes
GMP-ready configuration available	Yes
Scale transfer support	Yes
Platform scalability range	20L – 270 L

L4 – Regulatory, Compliance & Lifecycle

IQ/OQ/PQ support	Yes
Recommended service interval	12 months
Warranty period	12 months
Lead time	Approx. 12 months
Validation documentation available	Yes

Scale-Up.

The BioPilot is the bridge in the Applikon stainless steel scale-up series. Geometric similarity and consistent engineering design across BioBench (20–30 L), BioPilot (30–270 L), and BioProduction (up to 5,000 L) ensure reproducible process transfer at every stage — minimizing risk when moving from bench to production scale.

GMP Transition.

With a cGMP compliant design and full validation documentation (IQ/OQ/PQ support), the BioPilot is the preferred platform for bridging research processes into regulated manufacturing. Its electropolished interior surface (Ra ≤ 0.4 µm), SIP/CIP capability, and re-sterilizable sampling port meet the documentation and cleanliness standards required for GMP-ready processes.

GMP Manufacturing.

The BioPilot is suited for the production of clinical or commercial batches under GMP conditions at pilot scale. With working volumes from 7.5 L to 200 L, a Multi-Use platform design, and full validation documentation, it supports regulated manufacturing environments with high demands on traceability and process reproducibility.

Technology Transfer.

Pilot scale is the standard handover point when formally transferring a validated process between sites, teams, or organizations. The BioPilot simplifies this transition through standardized construction, consistent control architecture, and complete documentation — covering all SOPs and process knowledge required for a successful transfer.

CDMOs.

The BioPilot is an established platform for contract development and manufacturing organizations (CDMOs) producing biologics at pilot scale for clinical or commercial batches on behalf of pharmaceutical companies. Its cGMP compliant design and modular expandability support the high flexibility and documentation requirements typical of CDMO environments.

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Applikon stainless-steel bioreactors — product overview

Scale up your bioprocess with the BioPilot

The BioPilot is purpose-built to bridge the gap between bench-scale development and full production. Geometric similarity and consistent engineering design across the Applikon stainless-steel family — BioBench (20–30 L), BioPilot (30–270 L) and BioProduction (up to 5,000 L) — ensure that process parameters established at one scale transfer reliably to the next. For development teams, that means the bioprocess you locked on the BioBench runs the same way on the BioPilot, and the parameters validated on the BioPilot translate cleanly into production.

For organisations under regulatory or clinical timeline pressure, the impact is structural: scale-up risk drops sharply when the platform you’re transferring to has the same control architecture, the same sparger and impeller geometry options, and the same documentation lineage as the platform you’re transferring from. Whether you’re optimising media, refining process conditions or moving into small-scale clinical production, the BioPilot delivers the precision and reproducibility the next stage of your process demands.

Applikon BioPilot Stainless Steel Bioreactor

cGMP compliance built in, not bolted on

Pilot scale is where research becomes a product, which is why the BioPilot is built to cGMP-compliant standards from the ground up rather than retrofitted. The electropolished interior surface (Ra ≤ 0.4 µm) minimises biofilm adhesion and meets the cleanliness standards required for GMP-ready processes. SIP and CIP capability make the system suitable for repeated long-campaign operation under regulated conditions. Full validation documentation with IQ/OQ/PQ support simplifies qualification from day one, and the re-sterilisable bottom-mounted bellows drain plus optional re-sterilisable sample system ensure sterile sampling and harvest across the full campaign duration.

For Technology Transfer between sites, teams or organisations, the BioPilot is the standard handover point: standardised construction, consistent control architecture and complete documentation cover the SOPs and process-knowledge transfer required for a successful handover. For CDMO environments producing biologics at pilot scale for clinical or commercial batches, the BioPilot’s modular expandability and cGMP-compliant design support the high flexibility and documentation requirements typical of contract manufacturing.

Workflows

What is the BioPilot workflow?

The BioPilot workflow runs across three phases.

Configure. Specify the vessel at order time: cell-culture or microbial geometry, total volume (30 L through 270 L), drive system (magnetically coupled or optional mechanical seal), motor specification, sparger type (porous, L-sparger or ring-type), sensor format, and add-on packs (pressure control, weight control, feed control, perfusion). The 1 : 1 cell-culture vessels are sized for mammalian cell culture, stem-cell expansion, regenerative medicine and viral-vector production; the 2.2 : 1 microbial vessels deliver the higher tip speeds and gas-transfer rates demanded by high-density bacterial and yeast fermentations. Resea Biotec’s specialists work through the configuration with you to match the system exactly to your process and validation requirements. Lead time runs approximately 12 months — typical for a fully cGMP-compliant pilot-scale system.

Scale up. Receive the validated process from BioBench-scale development, lock pilot-scale parameters across pH, DO, temperature, agitation and feed strategy, and run clinical or commercial batches at the appropriate working volume — 7.5 L to 200 L depending on the configuration. All four cultivation modes — Batch, Fed-Batch, Perfusion and Continuous — are supported on the same vessel platform, controlled through Applikon’s ez2Control with Lucullus PIMS integration for traceable, reproducible operation across long campaigns. SIP/CIP cycles and the electropolished surface finish keep the system production-ready run after run.

Transfer. When the process is validated and the next stage is full GMP production, geometric similarity and consistent engineering design across the Applikon stainless-steel family let you transfer the locked process directly onto BioProduction-scale platforms (up to 5,000 L) — or hand the process formally to an external production site or CDMO. Standardised construction and complete documentation make pilot scale the natural formal handover point in technology transfer.

Why use the BioPilot?

cGMP-compliant by design — electropolished interior (Ra ≤ 0.4 µm), SIP/CIP, full IQ/OQ/PQ documentation, ready for clinical and commercial GMP batches
Seven cell-culture and microbial geometries — dedicated 1 : 1 and 2.2 : 1 aspect-ratio vessels sized for each cultivation type’s mixing and gas-transfer profile
Four cultivation modes on one platform — Batch, Fed-Batch, Perfusion and Continuous, controlled through ez2Control with Lucullus PIMS traceability
The standard tech-transfer handover point — geometric similarity to BioBench upstream and BioProduction downstream lets validated processes transfer cleanly between scales and between sites
Modular expandability — pressure control, weight control, feed control, biomass sensors and perfusion systems configurable to your process from day one

Pilot scale, done right — with Resea Biotec

The Applikon BioPilot is a cGMP-compliant pilot-scale stainless-steel bioreactor, available in 30 L, 40 L, 60 L, 70 L, 130 L, 140 L and 270 L vessels with working volumes from 7.5 L to 200 L — built for the formal handover point between R&D and full GMP production. Dedicated 1 : 1 cell-culture geometries and 2.2 : 1 microbial geometries, full IQ/OQ/PQ documentation, SIP/CIP and an electropolished interior (Ra ≤ 0.4 µm) make the BioPilot the standard tech-transfer platform across the Applikon stainless-steel family.

Pilot scale is the formal handover point in your scale-up pathway — the place where research becomes product, validation becomes routine and process knowledge moves between teams, sites and organisations. Resea Biotec is Switzerland’s official Applikon distributor and certified service partner — based in Recherswil, supporting customers across Switzerland with local stock, German-language technical support and on-site service.

Talk to our team and we’ll spec the right BioPilot configuration for your bioprocess, coordinate IQ/OQ/PQ documentation, and stay on hand for application, validation and maintenance support throughout the system’s life. Whether you’re moving a validated process from BioBench-scale into clinical batches, transferring to a CDMO, or preparing for full BioProduction-scale GMP manufacturing — we’ll help you get there. Lead time is approximately 12 months, so start the configuration conversation early.

Applikon BioBench & BioPilot — Pilot and production-scale bioreactor brochure

Full product brochure covering features, applications, configuration options and specifications for the Applikon BioBench and BioPilot stainless-steel bioreactor range — standardised vessels from 20 L to 270 L, plus custom-built systems up to 5,000 L.

PDF • 4.6 MB

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Applikon BioPilot Stainless Steel Bioreactor – 7 to 200 L, Modular and Scalable.

The Applikon BioPilot in Detail.

BioPilot pedigree — built by Applikon for cGMP-ready scale-up.

Easy operation with professional process control.