By operating on a fully digital platform, biopharmaceutical R and D labs can maintain optimal conditions for fermentation and/or cell culture within the bioreactor
Since early 2003, Broadley-James has quietly inked deals with key players in the life science industry to supply its BioNet bioreactor control system, the first digitally networked bench-top bioreactor for cell culture and microbial applications. EmersonProcess Management has now announced its key role: the BioNet system uses Emerson PlantWeb digital plant architecture and solutions.
The bioreactor control system is controlled by the PlantWeb DeltaV digital automation system that networks to devices like Brooks Instrument mass flow controllers (MFCs) through industry standard DeviceNet and Foundation fieldbus protocols.
By operating on a fully digital platform, biopharmaceutical R and D labs can maintain optimal conditions for fermentation and/or cell culture within the bioreactor.
The BioNet controller uses the DeltaV digital automation system for controlling and managing small to large arrays of BioNet utility towers.
Individual controllers can manage up to ten utility towers and can be sequenced to control an entire suite of bioreactors.
One key element of the automation solution is the Brooks Instrument mass flow controllers.
The Brooks Instrument mass flow controllers provide greatly improved control of gas mixing and flow rate with an accuracy of +/-0.7% or better.
These flow meters communicate their measurements and instrument status to the DeltaV-based BioNet controller via DeviceNet, which allows for active monitoring, trending, asset management and precise control.
The DeltaV system can also be networked to other intelligent field devices like Micro Motion Coriolis flow meters, Rosemount measurement instruments, and analysers using Profibus DP and Foundation fieldbus technologies.
Broadley-James selected process automation suppliers for BioNet based on analysis of the needs of the biopharmaceutical market.
"In the process end of this industry, reliability and predictability are pinnacle. "Downtime can cost you thousands of dollars.
"Cheaper doesn't do you any favours," stated Larry West, director of sales and marketing for Broadley-James.
"Ease of validation also proved to be crucial in the life science market. "Emerson won out in every category when compared to other providers".
Broadley-James assessed that digital communications would soon dominate process development, and PlantWeb with its DeltaV digital automation system was evaluated to be the leading technology.
At the process level, mass flow controllers were critical BioNet components, and numerous MFC vendors offer smart products that integrate into digital systems. Broadley-James wanted to know what other factors regarding mass flow controllers were important to customers in the life science market.
The company chose the Emerson Brooks MFCs based on factors gleaned from surveys of prospective customers.
Overall value topped the list, followed by technology, experience in life science applications, and reputation.
Reducing time to market. Monitoring the environment inside a bioreactor via intelligent devices on a digitally networked system offers insight as opposed to simply providing information.
Lab personnel can interpret data and status from pH and DO sensors inside the bioreactor through the DeltaV system, and make scientific decisions based on behavior.
"It's the difference between doing science and just doing chemistry," remarked West.
"The insight gained from digital automation significantly shortens the R and D phase of fermentation and/or cell culture process development and ultimately helps speed time to market".
Higher yield through tighter gas management.
Gas management takes high priority in the life science industry because it represents a means for maximizing resources as well as optimising batch yield.
Until recently the level of control for gases affecting the pH and DO of bioreactors was limited, and it's safe to say that yields were proven out.
The digitally networked process, on which the BioNet control system operates, breaks those limitations by providing improved control that results in higher yield.
pH and DO sensors inside the bioreactor send feedback instantaneously to the DeltaV system which then determines the best approach based on the BioNet solution model.
Gas management from the bus-enabled Brooks MFCs immediately adjusts the flow of gas to maintain an optimal environment for fermentation and/or cell culture.
Scaling up.
By creating the first digitally networked bioreactor control system for use in early phase cell culture development, Broadley-James has provided life science companies the first link to a completely digital fermentation and/or cell culture process. The bus-enabled Brooks Instrument MFC and DeltaV digital automation system used in the BioNet control system are capable of being integrated throughout every stage of development for fermentation and/or cell culture.
Bioreactor capacity might increase from three litres in the growth lab to 13,000 litres in the production facility but the key technologies remain consistent.
"Uniformity of hardware and automation architecture means uniformity of information," stated West. "Scientists in the R and D labs can now actually communicate with engineers in the production plant because they're using the same technologies for control.
"Behavior is managed consistently regardless of scale."
