WACKER and Gearbox Biosciences Unite to Launch Antibiotic-Free, High-Throughput pDNA Manufacturing Platform

WACKER and Gearbox Biosciences Unite to Launch Antibiotic-Free, High-Throughput pDNA Manufacturing Platform

(IN BRIEF) WACKER and Gearbox Biosciences have launched a partnership to co-develop advanced, antibiotic-free pDNA manufacturing techniques aimed at improving scalability, efficiency, and cost-effectiveness. Leveraging WACKER’s GMP biologics know-how and Gearbox’s Pop-Out-Plasmid® technology, the project will focus on streamlining workflows for antibiotic-free production and tackling difficult-to-manufacture plasmid sequences. Early activities include evaluating Gearbox’s system within WACKER’s PLASMITEC® toolbox at WACKER’s San Diego fermentation facility and Munich Biotechnology Center. Leadership from both companies highlight the collaboration’s potential to set new industry standards, reduce antibiotic resistance risks, and accelerate the supply of high-quality pDNA for cutting-edge therapies.

(PRESS RELEASE) MUNICH/TARTU, 7-Aug-2025 — /EuropaWire/ — WACKER and Gearbox Biosciences have entered into a strategic collaboration to pioneer next-generation plasmid DNA (pDNA) manufacturing processes that promise to transform the production landscape of this vital raw material for advanced therapeutics. Centered on developing antibiotic-free workflows and enabling the synthesis of challenging pDNA sequences, the partnership aims to deliver scalable, efficient, and cost-effective solutions that exceed current industry benchmarks.

Operating from its San Diego facility—equipped with microbial fermentation capacities of up to 650 L—WACKER is poised to undertake clinical-grade, antibiotic-free pDNA production following a rigorous evaluation phase (Photo: WACKER). By merging WACKER’s proven GMP biologics expertise, including its PLASMITEC® toolbox, with Gearbox’s novel Pop-Out-Plasmid® platform, the teams are set to tackle existing hurdles in pDNA scale-up, process throughput, and overall affordability.

“Joining forces with Gearbox Biosciences marks a pivotal step toward revolutionizing plasmid DNA manufacturing,” remarked Ralph Krafczyk, Nucleic Acids Specialist at WACKER R&D. “This alliance underscores our dedication to enriching the PLASMITEC® suite, ultimately empowering our clients—developers of life-altering therapies—to access superior pDNA at unrivaled quality and speed.”

Building on WACKER’s success with an antibiotic-free production system for recombinant proteins via its ESETEC® secretion platform, the joint initiative with GEA will spotlight innovative, antibiotic-free pDNA workflows and tackle sequences that have long challenged conventional methods. Leveraging each partner’s complementary strengths, the collaboration is committed to delivering more sustainable manufacturing practices while reducing lead times and elevating product integrity.

Arvi Jõers, Co-Founder and CEO of Gearbox Biosciences, added, “We’re eager to scale our laboratory breakthroughs to industrial volumes alongside WACKER. Our Pop-Out-Plasmid® technology—already proven in antibiotic-free protein expression—now extends to pDNA, addressing regulatory and societal concerns about antibiotic resistance in biomanufacturing.”

Already in motion, the collaboration’s early phase focuses on integrating Gearbox’s Pop-Out-Plasmid® into WACKER’s PLASMITEC® framework. Both organizations are fostering a spirit of innovation with the shared vision of democratizing access to high-quality pDNA for next-generation therapies, smoothing the path from bench to bedside. The newly inaugurated WACKER Biotechnology Center in Munich provides cutting-edge infrastructure to support this endeavor.

About Wacker Chemie AG

WACKER is a global company with state-of-the-art specialty chemical products found in countless everyday items, ranging from tile adhesives to computer chips. The company has a global network of 27 production sites, 21 technical competence centers and 46 sales offices. With around 16,600 employees, WACKER generated annual sales of around €5.7 billion in fiscal 2024.

WACKER operates through four business divisions. The Silicones and Polymers chemical divisions supply products (silicones, polymeric binders) for the automotive, construction, chemical, consumer goods and medical technology industries. Biosolutions, the life sciences division, specializes in bioengineered products such as biopharmaceuticals and food additives. Polysilicon produces hyperpure polysilicon for the semiconductor and photovoltaic industries.

For more information on WACKER’s biotechnology business go to: www.wacker.com/biologics

About OÜ Gearbox Biosciences

Gearbox Biosciences is a start-up company from Tartu, Estonia. The company has developed a proprietary Pop-Out-Plasmid technology for antibiotic-free protein and plasmid production. This technology can eliminate antibiotics from bioproduction and curb the spread of antibiotic resistance in the environment.

Gearbox Biosciences operates by licensing out the Pop-Out-Plasmid technology to its partners, who then use it to produce proteins or plasmids. In addition to being antibiotic-free, Pop-Out-Plasmid technology offers increased strain stability and inducer-free induction of protein production.

Media Contact:

Media Relations
Dr. Karsten Werth
Tel. +49 (0) 89 6279-1573
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Gearbox Biosciences
Arvi Jõers
CEO
Tel. +372 55 624 245

For more information on Gearbox Biosciences and Pop-Out-Plasmid technology go to: www.gearbox.bio

SOURCE: Wacker Chemie AG