Helaina
AACE Class 5-4
FEL-1
Helaina uses precision fermentation to make effera®, the world's first bio-identical human lactoferrin, now produced at metric-ton scale. Working with Roebling engineers, the Helaina team built a live, fully costed model of that production in their own workspace. Now they can test their scale-up options themselves instead of commissioning a study.
1,219 changes
to model assumptions executed instantly, without re-engaging consultants
6 weeks
saved in evaluation cycles, eliminating the wait time of traditional engineering studies
$50K
in consulting fees saved, replacing recurring external engineering retainer costs
Challenge
Helaina needed the ability to compare the paths to scale their process on the same engineering basis, with unit economics that would hold up in front of a capital committee. The traditional route to this is a multi-quarter engagement ending in a static report that is out of date the moment an assumption moves.
Solution
Roebling's engineers took Helaina's process documentation as the basis and built a live commercial-scale model, complete with financial models, dynamically updating with every change. Each scenario can be evaluated against the project success criteria and discarded until only the best option remains.
Results
Helaina's finance and engineering teams now work from one model rather than trading spreadsheets. CapEx and cost of production update as the solver runs, so the team can set a target and let the model size the plant that hits it. The model stays live in their workspace, ready for the capital decisions ahead rather than expiring like a report.
"Roebling has become a core tool in our commercial scaling strategy, helping us assess manufacturing options against our projected unit economics. It will be a valuable tool as we grow and continually reevaluate Helaina's optimal manufacturing strategy."
Taylor Burroughs
Chief Financial Officer, Helaina
The Approach
Built on the engineering Helaina already had, and built to keep working after handover.
Roebling's fermentation and chemical engineers were onboarded directly using Helaina's process documentation. Over a structured six-week ramp, dedicated training sessions and weekly office hours with a named engineer and customer success manager ensured total alignment.
The resulting model gives Helaina full control over facility design:
Input a target output, and the solver instantly resizes the plant, recalculating equipment lists, capital expenditure, operating costs, and overall financial returns in real time.
Equipment costs link directly to source quotes, building costs scale dynamically by area, and labor models are fully customizable line-by-line.
The model lives directly in Helaina's workspace and remains entirely theirs. Platform enhancements roll out weekly without altering the underlying numerical basis of existing models.
What the teams say
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