Metabolic engineering automated with PIXL Dark
Recombia Biosciences implemented an end-to-end metabolic engineering workcell by upgrading their standalone PIXL to PIXL Dark.
Introducing Recombia, a Lesaffre entity
Recombia Biosciences is a metabolic engineering company founded in 2019 by Stanford genome editing scientists and Lesaffre as a Joint Ventre. In 2022, Recombia was fully acquired by Lesaffre, the world’s largest manufacturer of yeast for breadmaking, extracts, brewing, winemaking and ethanol fuel, with a total of 10 business units and 6 breadmaking regions.
The partnership helped Lesaffre to expand their R&D pipeline and meet growing demand in the nutrition and biotech sectors. While in return, Recombia gained access to advanced facilities, including the largest biofoundry in Europe, located near Lille in the North of France.
“Recombia is interested in using advanced gene editing technologies for strain engineering. Specifically, we’re trying to engineer yeast to produce commercial metabolites that are of value to the Lesaffre Group,“ says co-founder, Bob St Onge.
Bolstered by the new partnership, and augmented by an additional lab established in Boston Massachusetts in 2023, Recombia has doubled down on its investment in metabolic engineering and synthetic biology. It has now launched two products with Lesaffre-affilated business units in the area ethanol fuel yeast and nutraceutical, with more in the pipeline. Hence now is a pivotal time to be scaling up its metabolic engineering capacity with cutting-edge lab automation.
The technology platform
Rational engineering strategies, based on mechanistic understanding of components, are helpful towards strain improvement. But they are rarely sufficient when used alone.
Recombia’s solution is to complement the specificity and versatility of rational design with the breadth of ‘target-agnostic’ approaches, as Hui Zhou, Head of Metabolic Engineering at Recombia, explains:
“At Recombia, projects usually begin with a rational engineering approach supported by careful techno-economic analysis. We take information from the biochemical and enzyme engineering literature, and from our own experience, and design genetic changes into prototype strains exploring a certain metabolic space. With the help of quantitative scaled-down models of fermentation and system biology, we then study the response space generated by our genetic changes.”
Recombia’s state-of-the-art technologies effectively potentiate donor-templated DNA repair to enable precise multiplexed genome editing. Ensuring the new sequence (the donor DNA) has accurately and efficiently replaced the previous sequence helps generate production-ready strains with the potential to scale almost seamlessly into industrial workflows.
“What we’ve learned from taking this systemic approach is that, of course, biology is complicated and often there are unpredicted consequences to making such changes. Combining rational approaches with either systematic unbiased screening or selection of large libraries of strain variants therefore gives us a much clearer picture of how well strains will perform in manufacturing conditions,” adds Massimo Merighi, Chief Bioengineering Officer for the company.
The automation challenge
Bob was one of the early pioneers of ROTOR+, Singer Instruments’ high density arraying robot. Its ability to reformat plates at a rate of nearly 1 million colonies an hour has seen ROTOR+ grow into somewhat of a secret weapon for the bioengineering community.
ROTOR+ helped take the sting out of library construction in the early days. But with the founding of Recombia, and multiple new projects on the horizon, Bob says consolidating those increasingly large collections has rapidly become the next bottleneck:
“We have several very large complex libraries that consist of many clones. We can use next generation sequencing to identify non-redundant sequence validated clones within that set. But what we end up with is potential candidates in the thousands or even tens of thousands.
“So in our Design, Build, Test, Learn cycle, the Test remains the bottleneck of the whole process. And we need to first reduce down the number of clones to a smaller more manageable set to increase feasibility.”
Recombia’s solution
Having recently taken on significantly more projects and expanded to a second location in Boston, it was clear Recombia needed to unlock more screening capacity.
Based on his positive experience with ROTOR+, Bob knew exactly where to turn:
“We’d had a great experience with the ROTOR+ in terms of technical support from Singer Instruments. So we took a shot at the PIXL, and it’s worked out really well for us.
“When we first looked at a robotic colony picker we wanted to take some of the large complex libraries that we were generating with gene editing technologies and reformat those into consolidated arrays of clones on agar plates.
“The main thing for us with colony picking was reproducibility and also dependability and the PIXL seemed to check both those boxes. The previous colony picker we had been using had some issues with reliability and also sterility. So we were also intrigued by the innovative design with the plastic filament feeding through and picking that way.”
Upgrading to PIXL Dark
Recombia’s holistic approach provides enhanced quality and frequency of edits, with the aim of reducing the cost and time to market. This greatly improves efficiency of the Test phase, by decreasing the number of unedited variants that compete for phenotyping capacity.
However, the size of those edited libraries is also limited by screening capacity. So to get maximum efficiency and balance this dichotomy, Recombia needed to hand over the job of managing the workflow to a Laboratory Information Management System (LIMS). This meant implementing a fully automated workcell, says Bob:
“Later on, when we were looking to fully-automate some of our cloning and strain engineering workflows, we were supported by our sister Biofoundry teams in France to upgrade to a PIXL Dark. The retractable door allows interaction with a robotic arm, so at that point you can run fully walkaway workflows.
“Just by being exposed to these kinds of instruments lets us think about experiments in a completely different way. And through being able to do things at a much larger scale we’ve actually developed innovative methods that we would not have developed otherwise.”
A Lesaffre Bioengineering Team