Switzerland-based Kühner, a leader in bioreactor innovation, uses three Watson-Marlow pumps in its 2500 L orbital shaken bioreactor for precise flow control, reliability, efficiency and compatibility with the bioreactor’s advanced automation systems.
The smooth integration with advanced automation systems allows for real-time monitoring and data-driven optimisation, ensuring consistent high-quality outputs and supporting scalable production.
Each strategically placed pump ensures nutrient delivery and culture broth removal to maintain the ideal environment for cell culture growth.
The pumps’ precise control of overflow rates enables consistent and reproducible bioprocessing conditions, which is essential to achieve high-quality outputs and scalability in production.
Connectivity
PROFINET connectivity, an advanced industrial ethernet solution to exchange data between controllers and devices, combined with user-friendly Watson-Marlow peristaltic pump technology, has brought significant advantages to Kuhner’s 2500 L orbital shaken bioreactor with more functionality than traditional digital control.
Julian Müller, Engineer for Automation of Products and Serial Production at Kühner, said: “With PROFINET, communication with the pumps is independent of additional hardware, which saves costs and reduces sources of error/risk of failure.”
“The PROFINET interface allows the pumps to be seamlessly integrated into the Siemens environment. The pumps can be integrated as fully fledged participants in the PROFINET topology without the need for additional components such as communication cards or gateways."
"This saves hardware and wiring effort, but also brings more transparency to the software architecture.”
Two Watson-Marlow 630PnN/R pumps are integrated into the SB2500-Z for their ease-of-use regarding the addition of acid, base and feed within the bioreactor (0.010–2.400 L/min).
The 730PnN/R pump, with its higher flow rates (1.000–33.330 L/min), is used to infill media and for inoculation — which require greater volume handling. The combination of the two pump models provides Kühner with the flexibility to manage different aspects of the bioprocess with precision and efficiency.
Julian Müller said: “Overall, the integration of Watson-Marlow pumps in the SB2500-Z bioreactor enhances the bioreactor’s performance, supports the automation and smart production systems, and ensures high-quality scalable bioprocessing.
“Owing to their flexibility and ease of use, the pumps can easily be integrated into the design and functionality of the bioreactor, which is why Kühner has been using the pumps for its orbital shaken bioreactor family from the lab scale (SB10-X) from pilot scale (SB200-X) to production (SB2500-Z) since 2011.”
PROFINET-enabled Watson-Marlow pumps reduce operational costs and improve process performance owing to
- easy to use software
- non-proprietary protocols
- easy integration, which minimises the cost of engineering, installation and commissioning
- common interfaces for all pump sizes.
Rolf Bächli, OEM Sales Engineer at WMFTS, said: “At the beginning of 2020, the first 630 and 730 PROFIBUS pumps were ordered. However, the communication between PROFIBUS and Kuhner’s PROFINET PLC (programmable logic controller) required an interface.
Early in 2022, we offered the first PROFINET 630 and 730 trial pumps to Kühner for free. This was a perfect solution and reduced set-up and installation efforts. Kühner is the first customer to order 630 and 730 PROFINET IP 66 pumps.”
Reliable bioprocessing
The SB2500-Z is being used to cultivate human, mammalian (for antibodies, vaccines), stem (for processed meat), plant (for antibodies, food supplements) and insect cells in a single-use bag.
Mabion SA, a biopharmaceutical company and contract manufacturer based in Poland, has installed two Kuhner SB2500-Z orbital shaken bioreactors for producing biosimilars, vaccines and other drugs under good manufacturing practice (GMP) conditions.
Kühner's bioreactors were also used to produce the first protein-based COVID-19 vaccines developed by the United States-based biotech company Novavax, Inc.
Nicolas Schlosser, Product Manager, Orbital Shaken Bioreactors, at Kuhner, said: “Customers appreciate the large 2500 L capacity, which allows for the scalable production of biopharmaceuticals and other biologics."
"This scalability is particularly beneficial for those transitioning from research and development to full-scale production.”
“The precise control offered by the integrated Watson-Marlow pumps ensures consistent and reliable bioprocessing conditions. Customers report high reproducibility of results, which is crucial to maintain product quality and meet regulatory standards."
“The SB2500-Z’s compatibility with advanced automation systems enables the real-time monitoring and control of bioprocesses. Customers value the ability to make immediate adjustments based on real-time data, leading to increased efficiency and a reduced risk of human error."
"Users highlight the bioreactor’s user-friendly design, which simplifies operation and maintenance. The intuitive interface and straightforward maintenance procedures minimise downtime and allow for smooth operation."
“The design of the 2500 L orbital shaken bioreactor with its orbital motion and surface gassing minimises shear stress and prevents bubble formation. As a result, there is no need for antifoam agents, which further simplifies the bioprocessing and enhances product quality.”
Watson-Marlow’s 530, 630 and 730 Ethernet I/P and PROFINET enabled pumps are fully compatible with advanced distributed control systems and leading brands of PLC, including Rockwell Automation, Emerson (Delta-V), Siemens and Beckhoff.
The pumps also support a broad range of sensor technologies such as Krohne.
