Building Your Process Block by Block: Why You Should Start a Technoeconomic Analysis (TEA) Before You Even Step Into the Lab

One of the biggest misconceptions I see among early-stage companies is that Technoeconomic Analysis (TEA) is something you do after you’ve run pilot plant trials. The reality? TEA should be one of the first things you do, long before you finalise defining your production process or even step into the lab.

TEA Can Guide Technology Selection From Day One

When startups start developing a bioprocess, they often assume that TEA is only useful once they have experimental data. But in reality, preliminary TEA results can shape early decisions, such as: 

✅ Which processing technologies to utilise 

✅ How different process configurations impact cost and scalability 

✅ What capital and operating expenditures (CAPEX & OPEX) look like at scale

By incorporating TEA early, you don’t just analyse feasibility, you actively design a more cost-effective, scalable process from the start.

Every Production Process Consists of Several Unit Operations and Unit Operations are like LEGO Blocks

Bioproduction processes consist of multiple unit operations, each a critical step in production. Think of unit operations as LEGO blocks, each unit operation has similar blocks that you can replace, and rearrange, and you can optimise the process by selecting the correct blocks and arranging them to build the best version of your process, in TEA we will call them modules.

Examples of Unit Operations and their interchangeable modules:

🔹 Fermentation 

• Stirred tank module

• Bubble column module, 

• Airlift module, 

• Packed bed module, 

🔹 Solid-liquid separation 

• Centrifugation module, 

• Filtration module, 

• Flocculation module, 

• Sedimentation module, 

🔹 Purification 

• Ion exchange module, 

• Nanofiltration module, 

• Electrodialysis module, 

• Chromatography module, 

• Crystallization module

🔹 Drying 

• Drum drying module, 

• Spray drying module, 

• Freeze drying module, 

• Fluidized bed drying module

Each of these unit operations has multiple technology options (modules) and each module has multiple variations. TEA allows you to quickly compare them before you commit to a technology.

For example, let’s consider a solid-liquid separation unit operation:

🔄 You are unsure about using a decanter centrifuge or a disk stack centrifuge. TEA can model both technologies, predicting their cost, and technical performance (efficiencies and losses) before you even run a pilot test or new equipment. 

🔄 You have already done pilot testing and your chosen technology is too expensive or inefficient. TEA makes it easy to swap in the model with a different separation technology module and immediately see the impact on costs and performance.

🔄 Solid-liquid separation technologies are outside your expertise. This is where working with an experienced “Process engineer- TEA consultant” can help you narrow down viable options, integrate them into a TEA model, and guide you toward the best technical and economic decision.

Mathematical Models as Decision-Making Tools

As mentioned above, in Technoeconomic Analysis (TEA), each unit operation can be modelled as a 'black box', a concept used in chemical engineering and process modelling that means that while the internal mechanisms of the operation may not be explicitly detailed within the TEA, the model captures the inputs, outputs, and key performance metrics that define its economic and technical impact. 

Each unit operation is built as a mathematical model representing the step with key performance metrics such as:

📌 CAPEX & OPEX estimates 

📌 Efficiency and recovery rates 

📌 Material and energy balances

Because these modules are standardized, if a TEA reveals that a selected technology is inefficient, too costly, or results in excessive losses, it can be swapped for an alternative without disrupting the entire model.

This flexibility means that TEA is not just a passive evaluation tool, it’s a dynamic framework that actively supports process optimization.

Building a Full Mass Balance, Even Before Pilot Plant Trials Begin

One of the key outputs of a TEA is a complete process mass balance, which estimates the material inputs, losses, outputs, and overall production potential of your process. If you have a full mass balance, you already have a clear data-driven foundation for:

✅ Scaling up production efficiently

✅ Sizing Equipment and estimating feedstock and utilities usage 

✅ Optimizing material and energy usage 

✅ Identifying cost-saving opportunities before they become problems

A well-developed TEA allows you to make critical scale-up decisions before committing time and money to pilot plant trials.

TEA Is a Strategic Advantage for Investors & Startups

Many startups only realize the value of TEA when an investor asks for it, by then, they’ve already made costly decisions that could have been optimized earlier. Smart investors increasingly expect TEA insights from day one, because they:

💰 Reduce risk by identifying financial or technical bottlenecks early 

📊 Help startups make more informed R&D decisions 

🚀 Ensure that technology is not just technically promising, but also commercially viable

Investors and stakeholders want to know not just that a technology works, but that it can be economically sustainable and scalable. TEA provides the necessary data to back up these claims, making it easier to secure funding and strategic partnerships.

Finally: TEA Is an Invaluable Tool for Every Growth Stage

Whether you’re at the concept stage, in pilot trials, or preparing for full-scale production, TEA is an essential tool that can save money, prevent costly mistakes, and accelerate commercialization.

In TEA unit operations are modules like LEGO blocks, you can replace and reconfigure and TEA helps you build the best process from the start.

As a TEA consultant, I help startups get on the right track from the early stages so they can make better decisions at every stage of development.

💡 If you’re working on an innovative bioprocess or deep tech project and want to ensure it’s scalable and cost-effective, let’s talk!

What are your thoughts? Have you used TEA early in your process development? 

Drop a comment below! ⬇️

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