Instrumentation of Bioreactor Online and offline Control

The bioreactor is considered an indispensable part of all kinds of bioprocesses. From the process of degradation of pollutants to the production of multiple substances such as food, pharmaceuticals, chemicals, feeds, tissues, and organs for biomedicine, etc., bioreactors are a must. To ensure the bioreactor works properly and the bioprocess is done properly, the suitable environmental conditions required for the bioprocess must be given. It is the bioreactor that provides an effective environment for the enzymes and allows them to culture into useful products as per requirement.

Instrumentation of Bioreactors

The main components typically used in a bioreactor are;

1. The bioreactor: The main part consists of a 3-liter glass vessel with stirrer assembly (for a 3-liter bioreactor specifically, and size subject to change), aeration assembly, baffles, sensors for enabling pH measurement, level and stirrer speed, and dissolved oxygen. 
2. An ADI 1010 Bio-Controller- The bio-controller is attached with a power unit and is used to measure all the variables used in the bioprocess. 
3. An ADI 1025 Bio-Console- It is used to support the actuators (like pumps and valves).

Off-Line and On-Line Control

Off-Line Control and its Measurement- After physical pretreatment processes like dilution and filtration, a sample of the substance used in the bioreactor is taken out and examined in a lab under sterile conditions. The entire process requires a lot of expertise and concentration and at any step of the process face any sort of problem, the efficiency, and accuracy of the results will decrease. The preparation for this analysis demands highly skilled personnel and a clear set of Standard Operating Procedures (SOPs) to ensure the results are accurate. Unless there are no other alternatives, the off-line measurement is not considered as a true Process Analytical Technology (PAT). In most cases, the off-line measurement is done to make sure the On-line/In-line process analyzers are accurate.

On-Line Control and its Measurement- This process is more efficient in terms of monitoring the process in real-time and also ensures a quicker and constant scope for monitoring of the sample used in the bioreactor. In the case of on-line measurement, the concerned sample which is to be tested and analyzed is diverted from the manufacturing setup process with a by-pass stream that is connected to the bioreactor and the sample may be returned later to the bioreactor. The entire measuring process is done by process sensors which are comparatively quicker than the off-line measuring system. This method also requires lesser skilled personnel and is much safer and more efficient. However, it must be noted that this process requires a different and unique setup in the bioreactor and for that reason, this measuring process can be uncommon. This process is less common than other systems like the in-line monitoring which does not require a separate by-pass stream diverted from the manufacturing section.

What is a Bioreactor?

The bioreactor is an apparatus used for growing organisms like yeast, bacteria, animal cells, etc. this apparatus is used in factories for the production of vaccines, antibodies, and pharmaceuticals. There are different kinds and sizes of bioreactors that are accordingly used for a particular purpose and volume of production. 

Types of bioreactor

• Continuous stirred tank fermenter
• Airlift fermentor
• Bubble column fermenter
• Fluidized-bed fermenter
• Packed bed fermenter
• Photobioreactor
• Membrane bioreactor

Stirred Tank Bioreactor

The stirred tank bioreactor is a commonly used bioreactor that primarily consists of two main parts; a cylindrical shaped vessel and a stirrer inside it.

Conclusion

Bioreactors are the apparatus used for the growing of living organisms and culture to produce useful products under favorable conditions. The bioreactors are also used in bioconversion processes where raw materials are converted into purposeful by-products. These instruments are very crucial in many industries for the manufacturing process as they provide a healthy and suitable biologically active environment for the bioprocesses. The homogenous environment they provide creates a fantastic chamber for the living organisms to grow and develop into different by-products. The usage of these instruments in the pharmaceutical and food processing industry is immense. Machines are installed to produce the products in large volumes. These machines are usually cylindrical and can be either anaerobic or aerobic. The entire process, however, must be done under proper safety and hygiene conditions and must be tested in regular intervals to ensure the quality and standard of the culture.