A Canada–UK collaboration is developing an AI-driven bioreactor platform designed to optimise biopharmaceutical manufacturing through smarter automation, real-time biosensing, and machine learning.

The 20-month initiative, known as BALANCE (Bioreactor Automation for Learning and Adaptive Networked Control of Experiments), brings together AI, digital twin models, automation, and bioreactor technologies. The project is supported by a $2 million grant from Innovate UK and NRC IRAP, as part of a Canada–UK Collaborative R&D programme.

Led by Labman Automation, the consortium includes Canadian biosensor developer Nicoya, UK-based CPI (Centre for Process Innovation), and Basetwo, a digital twin specialist. Together, the partners aim to create an integrated demonstrator platform that uses real-time data from bioreactors and sensors to drive adaptive process control.

Bioprocessing has long been a bottleneck in biologics development, often limited by slow feedback loops and inefficient experimental cycles. The BALANCE platform addresses this by using Basetwo’s machine learning models to interpret real-time sensor data and dynamically adjust experimental conditions in closed-loop bioreactor systems.

“Until now, sensing technology has been too slow and complex to enable truly reactive bioprocessing,” said Ryan Denomme, co-founder and CEO of Nicoya. “Label-free biosensing is critical to unlocking the potential for automation and AI to drive efficiency in biomanufacturing.”

The system will combine Nicoya’s Alto SPR biosensor with a modular sampling unit developed by Labman, allowing real-time molecular analysis and continuous feedback on yields. This data will feed into Basetwo’s digital twin platform to optimise bioreactor conditions in real time, cutting down on manual interventions and lab-based quality testing.

CPI will validate and benchmark the BALANCE system, helping ensure the platform’s commercial viability and scalability for large-scale biologics manufacturing.

“This is the next step for biologics and drug manufacturing, integrating Industry 4.0 approaches for bioprocessing,” said Thomas Smith, Head of Bioprocess Automation at Labman. “By combining advanced sensing, AI and automation, we aim to accelerate process development, improve consistency, and create smarter, more efficient biomanufacturing workflows.”

Brendan Fish, Director of Biologics at CPI, added: “Pharmaceutical companies know they must embrace digitalisation to stay competitive, but integrating digital technologies has been challenging in an industry that can be slow to evolve.”

The project represents a significant step toward autonomous, AI-driven biologics manufacturing, with potential implications for faster development, reduced costs, and more consistent therapeutic production.

“AI-enabled digital twins is the next frontier in intelligent manufacturing,” said Thouheed Abdul Gaffoor, CEO at Basetwo. “This collaboration moves us closer to autonomous biomanufacturing, cutting time, cost, and variability in producing life-saving therapeutics.”