High-Fidelity Process Simulation
Reliable. Industrial. Proven.

Simulate your reactor with SimVantage Bolt, plan the next scale with SmartScaler, or bring in our engineers for your toughest challenges.

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Developed and Validated with Industrial and Academic Partners

  • Novasign
  • Qubicon
  • Fraunhofer IPA
  • RCPE
  • TU Graz
  • TU Wien
  • RWTH Aachen
  • BOKU Wien
  • KTH Stockholm
  • University of Sydney
  • Université Paris-Saclay
  • IMC Krems
  • FH Campus Wien
  • HS Niederrhein
  • Provadis Hochschule

Challenge

Process design decisions are hard to test in a lab.

A reactor you build today stays in operation for many years, and so does every design mistake in it. Trying alternatives at full scale is rarely an option, because production runs under strict regulatory requirements and lab and pilot capacity is limited. A failed scale-up is expensive.

Process engineering teams use simulation to

  • 01Design a reactor around the process it will run
  • 02Get mixing and mass transfer right
  • 03Find out what slows down a production reactor
  • 04Take risk out of a scale-up
  • 05Skip experiments that a simulation can answer

Solutions

Three Ways to Work with Us

Use SimVantage Bolt to see the flow in your own reactor, and SmartScaler when you need scale-up numbers in seconds without running CFD yourself. If a question needs more than software, our engineers join the project.

Software · CFD

SimVantage Bolt

See how a reactor behaves before you build or change it. Bolt computes the flow from the physics, so it works for new designs as well as for troubleshooting.

  • Aeration, particles and free surfaces
  • Mixing time, kLa (oxygen transfer), gas holdup and Njs (just-suspended speed)
  • Imports STL and STEP, handles moving and deforming parts
  • Runs in the cloud or on your own hardware, scriptable in Python and Julia
Explore SimVantage Bolt

Software · Scale-up

SmartScaler

Move a process from lab to production scale. SmartScaler works with surrogate models trained on validated CFD, so the heavy simulation is done before you start.

  • Results in seconds
  • Compare scale-up strategies side by side
  • No CFD experience needed
Explore SmartScaler
SmartScaler results view with operating conditions and scaling fit
SimVantage engineering team

Service · Engineering

Consulting

Our engineers take on your reactor questions, from the first design to the running production plant.

  • Process design and reactor optimization
  • Scale-up strategy and troubleshooting
  • Numbers you can base a decision on
Explore Consulting

Results

Confirmed in Production, Published in Peer-Reviewed Journals

Case Study · Sandoz Kundl

Reactor Optimization in a 160 m³ Production Bioreactor

30% Shorter mixing time in a 160 m³ production reactor
20% Less energy used by the same reactor
3,740 MWh saved per reactor each year
Read the Full Case Study
Simulated mixing in the original (A) and optimized (B) reactor configuration
Configuration A → B

Consulting · Top-15 Pharma

€1.3 M Saved on experiments within one year at a top-15 global pharma company Explore Consulting

Science

Built on Science. Validated in Industry.

We develop our methods with universities and research institutes, then put them to work in production plants. Our work draws on five fields.

  • Mechanistic process modeling
  • Hybrid modeling
  • Engineering-scale reactor analysis
  • Research with academic partners
  • Validation in industrial plants
View Publications

Processes2026HS Niederrhein · TU Graz

Experimental and computational investigation of vortex formation in a single-stage Rushton turbine stirred tank reactor

Frontiers in Bioeng. & Biotech.2026TU Graz · RCPE · Takeda

Homogeneous shear distribution improves NK-92 cell cytotoxicity in a clinically relevant 2 L membrane-stirred bioreactor

AIChE Journal2026RWTH Aachen · Leibniz-HKI

Scale-up of Streptomyces species cultivations based on the morphological response to the energy dissipation rate

Applications

Engineering Decisions Supported by Our Models

  1. 01

    Reactor Design & Optimization

    Before you change a production reactor, you can try the change in the model. Our simulations show where mixing, mass transfer or power input hold the reactor back, so only modifications that work in the model reach the plant.

  2. 02

    Scale-Up Strategy

    Mixing and mass transfer change with every step from lab to pilot to production. SmartScaler and Bolt predict those changes for each scale, so you can plan the scale-up with numbers in hand.

  3. 03

    Troubleshooting & Root Cause Analysis

    When a process misbehaves, we vary one parameter after another in the model until the cause shows up. Development and production teams get to a fix sooner.

  4. 04

    Process Transfer

    Moving a process to another site usually means moving it to a different reactor. If we simulate the target reactor early, the differences show up before the first batch runs there, which makes the transfer less risky.

  5. 05

    Digital Process Understanding

    Hybrid models link the reactor simulation to your process data and show which conditions in the tank drive the performance of your process.

Contact

Are you facing critical process design questions? Discuss your challenge with our team.

Bring us an existing reactor you want more out of, or an industrial scale-up you are planning. We work on it together with your team, using models validated in production.

Book a Demo Contact Our Team