Lean design and smart automation for bioreactors
Over the past decades, Adam Fabriwerk has es tablished itself as a specialist for pre-assembled and tested modular skids that can be integrated into pharmaceutical production in a plug-and-play manner. The individually designed systems combine all the necessary process components – from pumps and valves to sensors – and thus enable precise workflows in highly sensitive pharmaceutical and biopharmaceutical production processes. Adam Fabriwerk has now implemented the complete system design of a bioreactor for a leading international pharmaceutical company for the first time.
Precision determines yield
Bioreactors – also known as fermenters – are key components in the production of medicines, vaccines and therapeutic proteins. Microorganisms, cells or enzymes are cultivated in them under controlled conditions. Precisely regulated parameters such as temperature, pH value and oxygen content are crucial. Only when these are optimally coordinated, the biological processes can run efficiently and lead to a high-quality, usable result. In addition, cell cultures are particularly sensitive to environmental conditions. This is another reason why the operating parameters of the bioreactor must be kept within narrow limits. Even the smallest deviations mean that the entire batch may not be used.
Reliable products, reliable partnership
The engineers at Adam Fabriwerk have been relying on components from Bürkert for many years to build their skids.
“We really appreciate their precision and reliability. In addition, we benefit both locally and inter nationally from the fast and competent support of the Bürkert team.”
Bürkert was therefore the first choice for the expansion of their portfolio to include fermenters. In addition to precise process control, the team around Vishal Wagh was also looking for solutions to simplify the automation of the bioreactor as well as its diagnostics and maintenance.
Simple installation with decisive added value
A key success factor for Adam Fabriwerk is the digital networking of the components: “All Bürkert devices communicate via the bidirectional büS network. This makes it possible to connect the control valves in series, which considerably simplifies cabling. Not only does this reduce effort and costs, but also potential sources of error,” explains Mr. Harish Thorat, Design Manager at Adam Fabriwerk. The valves are connected via valve islands of type 8652 AirLINE and are integrated into the higher-level process control system via an ME43 fieldbus gateway using PROFINET. The valve islands provide important information on the operating status, for example by monitoring the valve opening times. “This will enable our customers to detect changes in valve operation at an early stage and provide targeted support for preventive maintenance,” adds Harish Thorat.
The büS network enables the control valves to be connected in series, which greatly simplifies the cabling. The valves are operated and monitored via type 8652 AirLINE valve islands (shown on the side walls of the cabinet) and integrated into the higher-level process control system via a ME43 fieldbus gateway using PROFINET. The valve islands provide important information on the operating status. This enables the pharmaceutical end user to detect changes in valve operation at an early stage.
“The series connection of the control valves in Bürkert’s bidirectional büS network simplifies cabling considerably. This not only reduces effort and costs, but also potential sources of error.”
Reduced media losses, prevented foaming
In the bioreactor’s feed line for dosing the valuable media, Adam Fabriwerk has used type 2036 Robolux multiway diaphragm valves specially designed for controlling high-purity, sterile, aseptic media as well as steam and CIP media. Thanks to their extremely compact, space-saving design, they can be installed closer to the vessel and have minimal internal volume: “This avoids expensive product losses by reducing the risk of residues and therefore contamination of the production batches,” explains the Design Manager. Adam Fabriwerk relies on high-precision type 8763 pressure controllers to dose the antifoam agent, which prevents foam from forming inside the bioreactor. These devices, specially developed for low flow rates and therefore small dosing quantities, replace the peristaltic pumps previously used by Adam Fabriwerk for their skids. “This also significantly reduces maintenance costs, as the flexible tubes no longer wear out and need to be replaced regularly,” says Harish Thorat.
Calculation example
Comparison of hygienic block solutions and resulting media loss due to internal volume
Exceptional solution
The new bioreactor skids launched by Adam Fabriwerk clearly set themselves apart from the competition. The fully integrated systems are delivered pre-assembled and tested, which considerably cuts down on commissioning time at the customer’s site and the time required for system validation.
The Bürkert components used give the process automation a high degree of reliability combined with operational flexibility. “That is our claim. We don’t do average – we do awesome,” concludes Vishal Wagh.
With the modern Systemhaus in Pune, Bürkert offers its customers in India extensive local production capacities and engineering expertise.
Adam Fabriwerk‘s skids are fully integrated end-to-end solutions that fit seamlessly into aseptic applications in the pharmaceutical and cosmetics industries. They are pre-assembled and tested in the factory and delivered as complete systems ready for commissioning.
