Single-Use Bioreactor Integration

ZETA has extensive experience in the engineering of “hybrid” systems that combine stainless-steel and single-use technology. This approach enables high flexibility and stable performance, as demonstrated in a project with a customer in Switzerland. The fully customized solution involved the integration of four single-use bioreactors and, in a subsequent project, a second production line as a mirrored version of the primary system.

A fully functioning, GMP-compliant system was required, along with the implementation of customer-specific standards and requirements. Apart from routing of tubes, hoses and cables being a complex issue, the integration of single-use units into the overall automation system is challenging. Standard software packages provided by single-use equipment suppliers cannot always be natively integrated into the automation environment. This might easily lead to automation islands, which would cause considerable additional work over the entire lifecycle of the systems.

The ZETA automation approach to single-use technology enabled integration of the single-use bioreactors (50 L, 500 L, 2x 2000 L) and additional equipment (scales, TCUs) without creating automation islands. Customer-specific standards were implemented through intelligent automation strategies, enhancing overall process control. The hardware and software for automation were delivered as ready-to-use.

The project included the design and fabrication of a stainless-steel work platform with utility pipework for the cleanrooms. ZETA developed a space-saving design for the pipework and tubing. The routing of the pipework greatly improved the EHS aspect. The system was designed for ease of cleaning and maintenance, with ergonomic access to the single-use equipment.