Valent BioSciences Opens New Biorationals Plant In Iowa [Slideshow]

By Richard Jones|June 27, 2014

Valent BioSciences Corporation (VBC) officially opened the doors to its new Osage, IA, biorationals manufacturing facility on June 27. The $146 million plant, which the company calls “the largest purpose-built biorational product facility in the world,” will supply the majority of VBC’s products derived from fermentation. Those products were formerly produced by AbbVie Inc.

1 of 11

1 of 11

Valent BioSciences New Biorationals Plant

Valent BioSciences' new $146 million state-of-the-art biorational manufacturing facility in Osage, IA, opened in June 2014. According to the company, it is the largest purpose‐built biorational product facility in the world and will play an important role in the production of new products. Photo by Richard Jones. All other photos courtesy of Valent BioSciences.
2 of 11

Fermentation Tanks

Large‐scale fermentation is used to grow microorganisms using a proprietary process and sophisticated process control and monitoring. The fermentation process takes multiple days, with production time varying by the product. A proprietary media mix is inoculated with VBC’s proprietary organism strains, continually tested for purity. Valves and piping allow for multiple inputs including air and nutrients.
3 of 11

Fermentor Motor and Drive

Fermentation requires a significant amount of agitation powered by a motor and drive system mounted on top of the tank. The large hatch on the right, called the manway, gives technicians access to the tank between production runs.
4 of 11

Formulation Tanks

Once the proprietary recovery process is complete, the concentrated product slurry is stored in large tanks awaiting transport to the formulation facility. The slurry is offloaded into a tanker and delivered for finishing and packaging at the company's dedicated formulations partner, A‐Z Drying.
5 of 11

Boilers For Sterilization

Steam from the boilers is a critical element in the pre‐fermentation sterilization process for both media and equipment. Sterilization is a critical part of quality control.
6 of 11

Air Compressor For Aerobic Fermentation

Air is another critical element in the aerobic fermentation process. The amount of air required for optimal growth varies throughout the fermentation cycle and is controlled by the distributed control system, all monitored by the production staff throughout manufacturing.
7 of 11

Chiller For Managing Fermentation

Fermentation is a heat generating process tied to the metabolic activity of the organism being grown. This industrial chiller facilitates temperature control throughout the growth process.
8 of 11

Storage Tanks

Large storage tanks are used to house raw materials prior to use in the production process. Inputs for Valent BioSciences' products must meet strict quality control standards that contribute to the consistency of finished products.
9 of 11

Quality Control Labs

The Osage Quality Control Laboratories utilize microscopy as a tool to confirm the purity and integrity of products. Highly trained analysts confirm pure cultures for inoculation of fermentors, as well as acceptability of fermentation broth, slurry, and finished goods.
10 of 11

Sustaining The Insect Colony

Expert entomologists in Osage diligently maintain insect colonies to provide a continuous supply of insects for bioassay testing. Insects are maintained at various stages of their life cycles in order to ensure healthy and consistent populations.
11 of 11

The Caterpillar Bioassay Laboratory

Biorational products are complex mixtures of protein crystals and spores that have multiple modes of action, and the formulation conditions are key to obtaining high activity. Testing for activity against a stable colony of insects, at multiple points in the manufacturing process, ensures product performance and consistency.

Having its own manufacturing facility was an attractive option given the continued growth in the biopesticide sector, says VBC Executive Vice President and Chief Operating Officer Ted Melnik.

“Valent BioSciences has made a long-term, consistent investment in research and development, and we have long-term know how in positioning biorationals alongside conventional chemistry,” Melnik says . “To be successful, you have to be able to position both.”

Editors from Meister Media publications American Vegetable Grower, American Fruit Grower, and CropLife visited the plant to meet with VBC leaders and take an advance tour of the facilities in early June. The 130,000-square-foot building contains fermentation systems, a pilot plant for small-scale manufacture of products in development, quality control testing labs, and an insectary.

“The new Osage plant means true continuity from discovery through product development to manufacturing and delivery of new high-quality products to our global customers,” says VBC Vice President of Global R&D and Regulatory Affairs Warren Schafer.