Revolutionizing bioreactor controllers with Raman analyzers
Boosting efficiency with Raman technology and the Catalyx OpenBIO® Bioreactor Controller
A pharmaceutical company integrated more than 30 Endress+Hauser Raman analyzers across multiple sites, including Pennsylvania. The analyzers, including Rxn2 and Rxn4 models, were deployed in R&D and manufacturing. Raman data was incorporated into the company’s bioreactor control platform using the Catalyx OpenBIO® Bioreactor Controller, enabling real-time adjustments to feed rates. This integration optimizes cell growth conditions, ensuring consistent biological process performance.
Advantages of using Raman analyzers
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Implementing the Catalyx OpenBIO® Bioreactor Controller and the Raman analyzers and probes helped improve efficiency, maximize yields and the number of batches that could be processed, translating to an ROI of approximately $300,000 per unit yearly.
Challenges for bioreactor controllers
The primary challenge for the pharmaceutical company was to enhance process efficiency for technicians and scientists. Traditionally, samples were manually extracted from vessels, analyzed in a lab and then used to adjust feed rates. This manual process was time-consuming and prone to contamination, which could compromise the integrity of the samples and the accuracy of the data obtained.
Improving bioreactor controller process with Raman analyzers
The solution to these challenges for the pharmaceutical company rested in the Catalyx OpenBIO® Bioreactor Controller platform provided by Catalyx in tandem with Endress+Hauser’s Raman Rxn2 and Rxn4 analyzers and Rxn-10 probes. Using Endress+Hauser’s optical analysis measurement instruments and Catalyx’s platform, the pharmaceutical company can now read glucose concentrations from a bioreactor and use this data to make immediate adjustments, ensuring optimal conditions for cell growth.
How do bioreactor controllers integrate with lab automation?
Bioreactor controllers integrate with laboratory automation by bringing real‑time Raman data directly into the control platform, allowing the system to automate what was previously a manual, offline workflow. For example, the Catalyx OpenBIO® Bioreactor Controller connects with Endress+Hauser’s Raman analyzers and Rxn‑10 probes to continuously read critical parameters—such as glucose levels—and uses this information to automatically adjust feed rates and maintain optimal bioreactor conditions.
What features should I look for in a bioreactor controller?
Look for a controller that offers real‑time data integration (such as Raman‑based control), an open architecture that works with any vessel or sensor, OPC UA connectivity for smooth system integration, S88 recipe‑based operation for consistency and scale‑up, strong data integrity with audit trails and automation that eliminates manual sampling to reduce contamination risk and speed up batch processing.
What are the advantages of Raman spectroscopy?
Raman spectroscopy offers real‑time, in‑situ process transparency, letting you “see” chemical composition and reaction progress as it happens. It provides a highly specific molecular fingerprint, enabling precise identification of materials and subtle chemical changes. Raman requires no sample preparation, works in aqueous environments, is non‑destructive and can measure through glass or polymer packaging.
Endress+Hauser: An industrial automation company in the USA
Endress+Hauser is one of the largest industrial automation and process instrumentation companies operating in the United States. The company provides measurement and automation technologies for flow, level, pressure, temperature and liquid analysis, along with advanced digital solutions for process industries. With more than 650,000 ft² of US manufacturing space and a nationwide sales and service network, Endress+Hauser supports customers across industrial markets.
