An automated
system for the
enzymatic synthesis of beta-
lactam antibiotics from
penicillin G, comprising: an enzymatic
bioreactor configured for
continuous flow operation in which
penicillin G acylase (PGA) is immobilized on a porous support selected from
agarose, functionalized
silica nanoparticles, polymeric hydrogels or
magnetic nanoparticles, thereby ensuring prolonged
enzyme stability, controlled
diffusion and prevention of
enzyme washout; a
sensor array embedded in the
bioreactor for real-time monitoring, comprising optical, electrochemical, spectrophotometric and
fluorescence resonance energy transfer (FRET) based sensors, with the sensors continuously measuring reaction parameters such as pH, temperature,
substrate concentration,
enzyme activity and
product formation rate; an
adaptive control unit comprising a
microprocessor-controlled,
artificial intelligence (AI)-based predictive model, wherein the
control unit dynamically adjusts the substrate flow rate, buffer composition, temperature regulation, modulation of enzyme activity and pH
titration in response to real-time sensor data, thus ensuring optimal enzymatic efficiency and sustained yield of 6-
aminopenicillanic acid (6-APA); a product separation unit downstream of the
bioreactor based on
microfiltration, in which a selective membrane
filtration system isolates 6-APA from unreacted
penicillin G and by-products, thus enabling continuous
recovery and purification of the desired antibiotic intermediate; an automated substrate recycling module in which unconverted penicillin G is recovered and reintroduced into the bioreactor via an integrated spectrophotometric quantification
system, with the system measuring the residual
substrate concentration and dynamically adjusting the recycling flow rates to maximize substrate utilization and minimize waste; an enzyme regeneration module comprising a controlled buffer washing and reactivation mechanism that periodically restores enzymatic activity by means of
stabilizing agents selected from polyols,
amino acid derivatives or
cofactor solutions, wherein the regeneration module also includes an ultrasonic wave activation system to prevent enzyme aggregation and restore the native conformation of the immobilized PGA; a
blockchain-based data
logging system in which all process parameters, enzyme
activity measurements,
reaction conditions and production yields are recorded in an immutable decentralized ledger to ensure compliance with regulations,
traceability and
process safety; A scalable, modular bioreactor architecture in which several interconnected enzymatic reactor units operate in parallel. Each bioreactor is independently controlled but synchronized with the central, AI-based
process optimization module, enabling flexible, demand-driven
scalability of production.