Mapping distal mutations allowed us to extend the enzyme’s operational life by 40-fold, a critical factor for long-term industrial cycles.
Pharmaceutical
Optimizing Pharma Manufacturing with a Co-factor Regeneration System
The Challenge
An Inefficient Biocatalytic System
A pharmaceutical manufacturer was facing a pretty common problem in its field: their existing biocatalytic system was heavily reliant on an expensive, non-renewable co-factor that was consumed during the reaction and generated inhibitory byproducts.
This single-use approach made the chemical synthesis too inefficient and costly to be viable at scale. To move forward, the client needed a more sustainable and cost-competitive solution that could drastically reduce raw material overhead without sacrificing reaction yield.
The Solution
Zymvol’s team designed and implemented a novel enzymatic synthesis featuring an integrated co-factor regeneration system, allowing continuous in situ recycling of the cofactor rather than one-time use.
This cofactor recycling solution was built on a multi-enzyme regeneration cascade that converts low-cost substrates into active cofactor within the reaction vessel, maintaining high catalytic turnover while preventing inhibitory byproduct accumulation and eliminating the need for constant replenishment.
Results & Impact
- Increased Product Formation
The shift from a resource-limited batch process to a continuous regeneration cycle led to a massive boost in productivity. By maintaining optimal co-factor levels throughout the reaction, the system achieved 7x more product formation compared to the original setup.
- Dramatic Cost Reduction and Improved Sustainability
The ability to reuse an ordinary, low-cost co-factor transformed the project’s process economics. This transition not only lowered the direct cost of raw materials but also simplified downstream processing (DSP), making the synthesis more robust and environmentally sustainable. - Rapid R&D Turnaround
Moving from an inefficient process to a validated, high-performing system required only 3 months in total, driven by Zymvol’s 1-month in silico development phase. This rapid computational design, followed by successful experimental validation, allowed the client to move into the next phase of manufacturing without the typical delays associated with complex process redesign.
Performance Highlights7x
Product Formation
The new regeneration system drastically increased the total turnover number (TTN), delivering seven times the yield of the original process.
★
Affordable and reusable co-factor
By substituting expensive single-use reagents with a reusable, affordable alternative, the process achieved industrial-scale viability.
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