Since early 2003, Broadley-James has quietly been signing deals with key players in the life science industry to supply its BioNet Bioreactor Control System. This, says the company, is the first digitally networked bench-top bioreactor for cell culture and microbial applications. It has just been announced that Emerson Process Management is playing a key role in this as 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 such as Brooks Instrument mass flow controllers (MFCs) through industry standard DeviceNet and Foundation fieldbus protocols.
By operating on a fully digital platform, biopharmaceutical R& D labs can maintain optimal conditions for fermentation and/or cell culture within the bioreactor.
The BioNet Controller uses DeltaV digital automation system for controlling and managing small to large arrays of BioNet utility towers. Individual controllers can manage up to 10 utility towers and can be sequenced to control a suite of bioreactors.
One key element of the automation solution is the Brooks Instrument mass flow controllers. These provide greatly improved control of gas mixing and flow rate with an accuracy of ±0.7percent or better. The 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 such as 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 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,“ said 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.
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 behaviour.
"It's the difference between doing science and just doing chemistry,“ remarked West. "The insight gained from digital automation significantly shortens the R&D phase of fermentation and/or cell culture process development and ultimately helps speed time to market.“
Gas management takes high priority in the life science industry because it represents a means for maximising 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.
By creating the first digitally networked bioreactor control system for use in early phase cell culture development, Broadley-James believes it has provided life science companies the first link to a completely digital fermentation and/or cell culture process.
