Concept for recycling a small-scale plastic-based bioreactor in a close-loop – Technical approach

To accelerate biotherapeutic development whilst decreasing development time and project cost, small-scale multi-parallel bioreactors have been developed to maximize product yield and quality. These systems feature single-use plastic-based bioreactors for easy connection and fast turnaround. Despite well-known advantages, the perception of plastic and the lack of recycling options are raising concerns in the scientific laboratories’ community. One of the common objections to plastic circularity in life-science is the perceived “downcycling” effect of mechanical recycling. Therefore, the aim of this work was to establish the technical feasibility of a close-loop recycling concept for the main construction material of the small-scale bioreactor. Application tests (cell compatibility and cell culture) were performed and supported by quantitative physical and mechanical tests (tensile, melt flow index, light transmission). Results show that mechanically recycled polycarbonate could be re-used in the same application. A comparative life cycle assessment (LCA), based on a theoretical framework, showed with different scenarios that recycling would have a positive impact on Climate – Carbon – total within the boundaries. Even if the technical feasibility of such a concept is demonstrated through this study, several challenges remain for such a closed-loop recycling concept to be implemented at a commercial scale. • Perceived contamination is the biggest barrier to healthcare plastic recycling. • Including recycled content in healthcare plastic seems impossible today. • Small scale polycarbonate bioreactors vessels can be mechanically recycling. • Recycled polycarbonate is suitable for cell-culture application. • Recycling scenarios shows up to 35% positive impact on the “Climate Change - total”.