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Lab Design & Setup · India

Your Tissue Culture Lab,
Built End to End.

From the first site visit to the first clean culture. From a single converted room to a production campus: design, paperwork and clearances, protocols and media, IP, equipment and training, using the methods that run our own production laboratory.

Tell Us What You Need to Build →

ISO 5laminar-flow transfer zone
121 °C · 15 psivalidated media sterilisation
pH 5.8standard MS medium set-point
16 h / 8 htypical photoperiod, 25 ± 2 °C

Nothing Off the Shelf: Every Element Curated

We do not sell a fixed package. Each element of your lab is specified, sourced and tuned for your crops, output and site.

Floor plan & zoningCivil & interiorsHVAC & air handlingLaminar flow & transfer stationsAutoclaves & sterilisationMedia kitchenWater purificationCulture vessels & glasswareGrowth racks & lighting spectrumTemperature, humidity & CO₂ controlElectrical, UPS & backupHardening & greenhouseSOPs & quality recordsProtocols & mediaSignage, gowning & hygieneWaste & effluentSensors & automationSoftware & dashboardsStaffing plan & trainingDocumentation & certification file

Designed Around the Culture Cycle

Every room exists to protect one step of the plant's journey. We design backwards from the culture, not forwards from the equipment list.

Stage 0Mother plant

Selection, indexing, pre-treatment

Stage IInitiation

Surface sterilisation, aseptic establishment

Stage IIMultiplication

Repeated subculture on cytokinin-balanced medium

Stage IIIRooting

Auxin-driven root induction

Stage IVHardening

Transition from humid vessel to open air

Reference Layout: One-Way Flow

Material moves from dirty to clean to growing, and never back. This is the logic behind every floor plan we draw; real layouts are fitted to your building.

1 Wash &Sterilise 2 MediaPreparation 3 Transfer Room(positive pressure) 4 CultureIncubation 5 Growth Room 6 Hardening Area autoclave · oven · RO balance · pH · stirrer laminar flow · ISO 5 observation racks lit shelves · 25 ± 2 °C · photoperiod shade · humidity · irrigation DIRTYCLEANGROWING Personnel enter through a gowning lobby (not drawn). Staff and materials never cross backwards.
Illustrative schematic, not to scale. Final layout depends on your site, crops and output.

Design Parameters We Specify

Typical starting points for plant tissue culture. We adjust them to species, scale and site.

AreaParameterTypical specification
Transfer roomWork-zone air qualityHEPA-filtered laminar flow, ISO 5 (Class 100) at the work surface; positive pressure relative to adjoining rooms
SterilisationMedia and toolsSteam autoclave at 121 °C, 15 psi; hold time set by volume (commonly 15 – 20 min)
MediaChemistryMS or species-specific basal salts, pH adjusted to about 5.8 before autoclaving, agar 0.7 – 0.8 % or liquid
WaterQualityRO followed by DI or distilled water for media preparation
Growth roomTemperature25 ± 2 °C, air-conditioned with backup
Growth roomLightCool-white LED or fluorescent, roughly 30 – 60 µmol m⁻² s⁻¹ at shelf level, 16 h light / 8 h dark for most species
HardeningTransitionHigh humidity with gradual reduction, shade 50 – 75 %, sterile or low-nutrient substrate
PowerResilienceDedicated circuits and UPS or generator for autoclave, laminar flow and growth-room cooling

What the Engagement Covers

Nine stages. You can take the full programme or pick the stages you need.

1Feasibility & Site Survey

  • Business and crop case: species, target plantlet output, market and phasing
  • Site assessment: building condition, floor area, ceiling height, power and water availability
  • Climate and contamination risk review for the location (humidity, dust, ambient temperature)
  • Written feasibility note with a recommended lab tier and phased build plan

2Facility Design & Layout

  • Zoned floor plan: washing, media preparation, sterilisation, transfer room, growth room, hardening area
  • One-way personnel and material flow to limit contamination
  • Civil and interior specification: epoxy or vinyl flooring, wall and ceiling finish, sealed joints, door and pass-box positions
  • HVAC and positive-pressure design for transfer and culture rooms, with air-handling and filtration options
  • Drawings and a bill of quantities your contractor can price against

3Utilities & Infrastructure

  • Electrical load calculation, distribution board, earthing, dedicated circuits for critical equipment
  • UPS and generator backup sizing for growth rooms and autoclave cycles
  • Water: RO and DI/Type II purification, storage, drainage and effluent handling
  • Compressed air, gas and lighting layout for growth shelves

4Equipment Specification & Procurement

  • Specification sheet with capacity, make-neutral performance criteria and acceptable alternatives
  • Core equipment: laminar air flow cabinets, autoclaves, hot air oven, analytical and top-pan balances, pH and EC meters, magnetic stirrers, water bath, refrigerator and freezer, microscope
  • Growth room fit-out: racks, LED or fluorescent lighting, photoperiod timers, temperature and humidity control
  • Glassware, culture vessels, tools and consumables for the first production cycles
  • Vendor shortlisting, quotation comparison and delivery coordination

5Media Kitchen & Input Supply

  • Media preparation workflow, storage and labelling system
  • Starter stock of MS, WPM and other media, plant growth regulators, agar and reagents from our own laboratory
  • Ongoing supply agreement so inputs stay consistent with the protocols we hand over

6SOPs, Quality & Biosafety

  • Standard operating procedures for sterilisation, aseptic transfer, media preparation and room cleaning
  • Contamination monitoring and record keeping formats; batch and traceability sheets
  • Safety practices for chemicals, autoclaves and electrical equipment
  • Guidance on the permits and registrations relevant to your intended use

7Protocols & Species Transfer

  • Species-specific protocols for initiation, multiplication, rooting and acclimatisation, validated in our own production lab
  • Starter cultures or mother-stock guidance, where available for your crop
  • Trial runs and troubleshooting during the first cycles

8Training & Handover

  • Hands-on training for your technicians in our laboratory and on your site
  • Supervisor training in planning, costing and yield tracking
  • Commissioning checklist: every item tested and signed off before handover

9Hardening & Ongoing Support

  • Primary and secondary hardening area design: shade, humidity and irrigation
  • Post-handover technical support, periodic audits and expansion planning
  • Optional Lab Management Software licence for batch, stock and cost tracking

Types of Labs We Build

From one converted room to a production campus. Start at the size that fits your budget and crop plan, and we design the first step so it can grow into the next.

1

Single-Room Lab

Footprint
Converted room, about 150 – 400 sq ft
Suited for
Learning, trials, small batches, a few thousand plantlets a month at most

One laminar flow cabinet, a compact autoclave, lit growth shelves and a media corner, all in one controlled room. The lowest-cost route to start real culture work, and the best place to prove a protocol before scaling.

Training & pilotLowest capex
2

Container / Modular Lab

Footprint
20 ft or 40 ft insulated unit
Suited for
Small to medium commercial output; sites with no suitable building

A factory-fitted, insulated container divided into media, transfer and growth zones, with HVAC and electrical pre-installed. Delivered ready to plug in, relocatable, and expandable by adding units. Good for leased land, remote farms and fast starts.

Fast deploymentRelocatable
3

Small Commercial Lab

Footprint
About 1,000 – 3,000 sq ft
Suited for
One or two crops, tens of thousands of plantlets a month

Separate wash, media, transfer and culture rooms with one-way flow, a proper hardening area and written SOPs. The usual first commercial step for nurseries and agri-entrepreneurs.

Production-readyPhased growth
4

Commercial Production Lab

Footprint
About 5,000 – 20,000 sq ft
Suited for
Multi-crop production, lakhs of plantlets a month

Several transfer stations, large controlled growth rooms, a dedicated media kitchen, positive-pressure air handling, quality records and batch traceability, and greenhouse hardening capacity.

Multi-cropQuality systems
5

Mass-Production / Industrial Lab

Footprint
Multi-acre campus
Suited for
Millions of plantlets a year; contract and export supply

Zoned campus with automated media dispensing and washing, large-scale culture rooms, optional bioreactor or temporary-immersion systems, in-house indexing and QA labs, utility redundancy and hectares of hardening and nursery. Designed for certification and audit from day one.

Automation-readyAudit-ready
6

Research & Specialty Lab

Footprint
Custom
Suited for
Universities, institutes, germplasm and breeding programmes

Tissue culture plus virus indexing, molecular and analytical support, cryo or slow-growth germplasm storage, and documentation suited to publication and grant requirements.

Research-gradeGermplasm

Footprints and outputs are indicative and vary by crop, subculture cycle and layout. We confirm them in your feasibility note.

Paperwork, Clearances & Certification

A lab that cannot legally sell plants is only a cost. We map which registrations and approvals apply to your state, structure and crops, prepare the documentation and coordinate the process with you and your advisers.

AreaWhat it typically involvesOur role
Entity & businessCompany, LLP or proprietorship; Udyam (MSME) registration; GST; bank and statutory registrationsChecklist and sequencing; coordination with your CA or company secretary
Land & buildingLand-use or conversion status, building plan approval, panchayat or municipal permissions, trade licenceDrawings and technical notes your approvals need
UtilitiesElectricity connection and load sanction, water source permissionsLoad calculation and utility specification
Safety & environmentFire safety clearance, state pollution control board consent where applicable, effluent and waste handlingSafety design, waste-handling plan, supporting data
Nursery & plant materialState nursery or seed-plant registration and licences where applicable, plant material sourcing recordsApplication support and record formats
Tissue culture certificationRecognition of the production facility and virus indexing under the DBT National Certification System for Tissue Culture Raised Plants (NCS-TCP), with accredited testingDesign the lab and records to meet recognition criteria; prepare for inspection
Quality systemsDocumented SOPs, batch records, traceability; ISO 9001-style quality management; ISO/IEC 17025 for testing labsBuild the documentation system and train your QA lead
Quarantine & tradeImport permits and quarantine for germplasm, phytosanitary certification for export, customs and IEC for tradersDocumentation guidance and process mapping
Plant varietiesRegistration and benefit-sharing considerations under the Protection of Plant Varieties and Farmers' Rights Act, 2001, and biodiversity-related permissions for certain speciesFlag what applies to your crops and refer to specialist counsel

Requirements differ by state, crop and business model, and rules change. We coordinate and prepare; formal legal advice should come from your own counsel.

Protocols, Methods & Media

Equipment does not make plants. Protocols do. We hand over the method as well as the room.

Species-specific protocols

  • Initiation, multiplication, rooting and acclimatisation, written step by step
  • Explant choice, sterilant concentration and exposure times, subculture intervals
  • Media formulations and growth-regulator schedules per stage, with expected multiplication rates
  • Troubleshooting tables for contamination, browning, vitrification and somaclonal variation

Media & inputs

  • MS, WPM, B5, DKW, NN and custom basal media, prepared in our laboratory or taught for in-house preparation
  • Plant growth regulators, vitamins, agar and gelling alternatives, with lot-wise quality records
  • Ready-to-use and premix supply, so early batches run on consistent inputs

Quality methods

  • Contamination monitoring and root-cause logging per batch
  • Virus indexing strategy and clean mother-stock programmes for crops that need them
  • Genetic-fidelity checks and subculture limits to control variation

Scale-up methods

  • Costing and yield models per plantlet, from vessel to hardened plant
  • Liquid culture, bioreactor and temporary-immersion options for suitable crops
  • Hardening protocols, substrate and irrigation schedules, survival tracking

Intellectual Property & Licensing

Who owns what should be written down before the first culture is started.

What you receive

  • A licensed, documented set of protocols for the agreed species, for use in your facility
  • SOPs, templates and training material under a clear licence
  • Your own batch data and records, which remain yours

How it is protected

  • Engagements begin with an NDA before technical detail is shared
  • Licence terms define permitted use, sub-licensing, improvements and confidentiality
  • Third-party variety, trademark and patent issues are flagged early so they do not become surprises later
  • Terms for improvements you develop on top of our protocols are agreed in writing

People & Training, End to End

A lab is only as good as the people running it. Training starts before construction and continues after commissioning.

Before buildOwner & manager briefing

What the lab will demand, hiring profiles, costing

Hands-onTechnician training

Aseptic technique, media preparation, subculture, in our laboratory

On siteCommissioning runs

First batches run alongside your team

SupervisorsQA & production control

Records, contamination analysis, planning, yields

After handoverRefreshers & audits

Periodic review, retraining, expansion support

One Software for the Whole Lab: Control, Manage, Sell

Every lab we build can run on the Phytolabs Lab Manager: IoT control of the environment, laboratory management of every batch, and sales management of every plantlet, in one system and one login.

IoT Control

Environment & equipment

  • Sensors for temperature, humidity, light and CO₂ in growth rooms and hardening areas
  • Automated lighting photoperiods, cooling, humidifiers, irrigation and fogging
  • Live dashboards, threshold alarms by SMS or app, and a full environmental log for audits
  • Power and equipment monitoring: autoclave cycles, UPS state, door and pressure status
  • Local control that keeps working if the internet drops
Lab Manager

Batches, protocols & people

  • Accessions and batches from initiation to hardened plant, with full subculture history
  • Subculture scheduler and daily work lists for technicians
  • Contamination records and analysis by crop, operator, cabinet and period
  • Media recipes, lots and stock; consumables and reagent inventory
  • Barcode or QR labels, SOP library, staff roles and training records
  • Yield, cost-per-plantlet and capacity planning reports
Sales Manager

From stock to customer

  • Live plantlet availability by species, stage and ready date, linked to batches
  • Customer records, enquiries, quotes, advance orders and waitlists
  • Order allocation from specific batches with full traceability
  • GST invoices, payments, dispatch and delivery tracking
  • Pipeline and demand reports that feed the production plan

The suite is configured to your lab: modules, sensors and dashboards are chosen with you, and can be added as the lab grows. Our existing Lab Manager covers the laboratory core today.

How to Start

Complete the requirements questionnaire. It takes about ten minutes and covers your site, crops, volumes, timeline and team. We review it before the discovery call, so the call is spent on decisions rather than basics. Engagements begin with an NDA.

Lab Requirements Questionnaire

Tell us roughly what you want to build. No obligation, and the answers stay confidential.

Start the Questionnaire →

Common Questions

How much does it cost to build a tissue culture lab in India?

It depends mainly on the target output, the state of the building and the equipment you choose. A small learning lab and a commercial production lab differ by an order of magnitude. Complete the requirements questionnaire and we will come back with a rough range for your case.

Can you work with a building I already have?

Yes. The site survey tells us what can be reused and what needs civil or electrical changes. Many projects convert an existing room or shed.

Do you supply the equipment?

We specify it, shortlist vendors and compare quotations. You decide where to buy. Media, growth regulators and consumables can be supplied from our own laboratory.

Will you teach my team?

Yes. Training for technicians and supervisors is part of every engagement, along with protocols for your crops.

Do you work outside Tamil Nadu?

Yes. We take projects across India. Site visits are planned around the survey and commissioning stages.