Bioprocess Control Switching Between Model and Atline Sampling
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Solution Overview
Problem
Bioprocesses face challenges in efficiently controlling critical quality attributes and process parameters due to slow and costly atline measurements, which can lead to batch failures and increased resource consumption, while model-based control may result in reduced certainty and potential waste if deviations are detected too late.
Innovation Solution
A hybrid control method combining model-based and sample-based controls, where model-based control is validated by statistical checkpoints, switching to sample-based control when quality indicators are not met, and using atline analysis to verify model predictions, with recalibration of sensors if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If atline measurements are used to control the bioprocess, then measurement accuracy is improved, but measurement speed decreases and resource consumption increases
Solution Approach 1:
The patent combines model-based control and sample-based control into a hybrid control system. The model-based control provides continuous monitoring and predictions, while the sample-based control provides periodic validation and calibration. This merging allows the system to achieve both high measurement speed (through continuous model-based monitoring) and high measurement accuracy (through periodic atline sampling), resolving the contradiction between measurement speed and measurement accuracy.
2Productivity
If model-based control is used, then productivity is improved through continuous monitoring, but reliability decreases due to model deviations from reality
Solution Approach 1:
The patent implements a feedback mechanism where atline sampling results are used to validate and update the model predictions. The system continuously compares model-based predictions with actual atline measurements, and when deviations are detected, the model is recalibrated or the control switches to sample-based control. This feedback loop ensures that the model remains reliable while maintaining continuous monitoring capability.
Solution Approach 2:
The control system dynamically switches between model-based control and sample-based control based on the validity of the model. When the model is validated through statistical checkpoints and shows good agreement with atline measurements, the system operates in model-based mode for high productivity. When deviations are detected, the system transitions to sample-based control to ensure reliability. This dynamic adaptation resolves the contradiction between productivity and reliability.
3Reliability
If atline sampling is performed frequently, then reliability is improved through validation, but resource consumption increases
Solution Approach 1:
Instead of performing atline sampling continuously or at every control decision point, the patent applies partial action by conducting atline sampling only periodically and only when necessary for validation. The system uses statistical checkpoints to determine when sampling is needed, performing sampling at a reduced frequency while still maintaining sufficient reliability for control decisions. This approach ensures control certainty is improved through validation while minimizing bioproduct consumption.
Data Source
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AI summary
The invention relates to a method for controlling a bioprocess (1), wherein in a model control routine (5) a bioprocess control unit (4) controls at least one process parameter (6) of the bioprocess (1) according to a model-based control loop (7). It is proposed that during the model control routine (5) the bioprocess control unit (4) repeatedly performs a first evaluation (13) of the model-based control loop (7), that if a first decision criterion is fulfilled, the bioprocess control unit (4) switches from the model control routine (5) to a sample control routine (15), that in the sample control routine (15) the bioprocess control unit (4) controls the bioprocess (1) according to a sample-based control loop (23), that at least one sample input parameter (24) of the sample-based control loop (23) is derived from a measurement value.