Advanced process control software in biotechnology

Automated advanced process control allows bioprocess control in real time

Advanced process control software enables the implementation of powerful model-based controllers for bioprocesses. These adaptive controllers and online monitoring solutions offer an effective extension of bioreactor and process control systems (SCADA, DCS).

As a result, production plants, pilot plants and laboratories can implement Process Analytical Technologies (PAT) and Quality by Design (QbD). Hereby quality parameters and performance indicators are reproducibly stabilised at a high level. In addition this increases the profitability of the plant operation and the efficiency of the process development.

Application of advanced process control Effect on the process
  • Enables online monitoring of process parameters which are not measurable or measurable to a limited extent only
  • Creates transparent processes
  • Increases opportunities for advanced process control
Nutrient feed control
  • Increased cell vitality and product yield
  • Reproducible by-product profiles and patterns of glycolisation
  • Accelerated process development and scale-up
  • Online optimisation of operation conditions and process parameters as a reaction on the variance of the seed culture, the quality of raw materials and changes in the production schedule.
  • Automated and early detection of faults, sensor errors, drifts / trends and of process anomalies
  • Ensures a reproducible process in optimal operation conditions
  • Compensates different raw material qualities and the variance of seed cultures
  • Reduces the usual variance resulting from a manual control by operating staff

Modular software facilitates a quick implementation and qualification of individually tailored solutions of advanced process control

Just as a regular controllers, advanced process control software is operated simultaneously to the on-going process. It records measurements in cyclical intervals and processes those into output parameters. These take an effect on the process in real time (for example as manipulated variable of an actuator or as a setpoint for a secondary control loop). At the same time these calculated outputs can be made available to the operating staff for their information. In order to be able to exchange those data with the plant the advanced process control software is connected to it via an interface.

Typically there are two different alternatives available:

  • The advanced process control software is connected to the process or bioreactor control system via a suitable interface. In this case operation and parameterisation occur directly via the existing control system. Alternatively the advanced process control software can be operated directly via its own user interface.
  • The other option is to connect the advanced process control software directly with the actuators and sensors (stand-alone operation). In this case the operation and parameterisation occur directly via the user interface of the advanced process control software platform.

That way the advanced process control software can easily be integrated in any plant or control structure. For application in the field of GMP engineo is pleased to offer this service including documentation and qualification.

From experience we can say that the advanced process control software only very rarely requires any maintenance work. For all eventualities engineo offers a 24 hour support service.