Bioprocess Monitoring and Control

Overview

Bioprocess monitoring and control is crucial to maintain an optimal cellular environment within bioreactors. There are several key parameters which influence culture growth and product formation. They include pH, dissolved oxygen (DO), temperature, as well as the concentrations of nutrients and byproducts. These process parameters are monitored using sensors, and control strategies are implemented, to maintain the parameters within a specified range. However, designing an effective bioprocess control strategy can be complex and involve a number of important considerations. These include decisions on the control loop design, the types of sensors, and the bioprocess control software. Here, you can find expert knowledge on the optimization of bioprocess monitoring and control strategies

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Why is bioprocess monitoring and control important?

Monitoring and controlling critical process parameters is needed to create a culture environment that ensures maximum productivity. For this to be achieved, key parameters and their setpoints should be identified and incorporated into the bioprocess design. This allows for product yield and quality to be maximized in a reproducible manner, which is important to minimize costs for raw materials, avoid failed batches, and as a result be time- and cost-efficient.

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How does bioprocess monitoring and control work?

Optimal bioprocess control is achieved using feedback control loops. Here, the sensors within these loops continuously monitor the system’s response, providing automated parameter control without the need for human intervention. Get an overview on bioprocess monitoring and control in our webinar.

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What are feedback control loops? And how can these improve bioprocess monitoring and control?‌

Feedback control loops are used to control process parameters at setpoint. Essentially, these involve the use of sensors that monitor process parameters, transmitting the recorded value to a bioprocess control software integrated into a bioprocess control system. Together, the bioprocess control software and system regulate actuators, which can be for example pumps, valves, or drives, to adjust the parameter back to its optimal level. Feedback control loops are preferred over non-feedback systems, as the sensors within these loops continuously monitor the control system’s response, providing automated parameter control without the need for human intervention.

Which process parameters can be controlled with a feedback control loop?‌

How are parameters monitored in real-time?‌

How and why are parameters monitored offline, after taking a sample?‌

Which parameter setpoints should I use for my process?‌

Which bioprocess parameters are relevant?

There are several key parameters which are typically monitored in a bioprocess, including

Physicochemical parameters, like pH, dissolved oxygen (DO), temperature
Nutrient concentrations, such as glucose and glutamine
Byproduct concentrations, such as lactate and ammonia
Information about the culture, such as biomass, viability, product concentration
Parameters relevant for conducting the bioprocess, such as liquid level and foam formation

Find more detailed information about why and how to control some of them here:

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DO control

The dissolved oxygen concentration is a key process parameter for culture growth. Find out more about strategies to control it.

pH control

Most organisms have a narrow pH optimum. Get detailed information about controlling the pH of the culture medium in a bioprocess.

Glucose control

Glucose is the most important energy source for many cell types and organisms used in the biopharmaceutical and biotech industry. On this page you find more information, on how to automize culture feeding.

Eppendorf solutions for streamlined bioprocess monitoring and control

The Eppendorf bioprocess systems help you optimizing your process monitoring and control strategy and be as flexible as possible. They facilitate the use of various sensor types from different vendors. The Eppendorf bioprocess control software packages facilitate development of tailored control strategies.

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With Eppendorf bioprocess systems and software* you can

Use analog as well as digital Mettler Toledo ISM^® and Hamilton ARC^® sensors
Use optical as well as electrochemical and polarographic sensors for pH and DO, respectively
Seamlessly integrate various sensor types
Develop scripts for tailored process control loops
Benefit from software features for simplified sensor calibration and judgement of sensor health

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^{*compatible sensor types and software features may vary between the bioprocess systems}

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