In-situ Sensor Integration in Single-Use Bioreactor Head Plates
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Solution Overview
Problem
Commercially available single-use small volume bioreactors lack the capability for in-situ monitoring of metabolites like glucose, requiring off-line sampling which increases handling efforts and contamination risks, and limits the ability to monitor glucose levels in real-time.
Innovation Solution
Incorporating one or more in-situ sensors, such as an electrochemical and/or enzyme-based glucose sensor, directly in contact with the cultivation medium, allowing for continuous glucose monitoring and reducing the need for off-line sampling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If off-line sampling is used to monitor glucose levels, then the bioreactor can be operated with simple sensor configuration, but handling efforts increase and contamination risk increases
Solution Approach 1:
The reactor head plate is designed as a multi-functional component that integrates multiple sensor ports and sampling ports into a single structure. This allows the bioreactor to perform both cultivation and multi-parameter monitoring functions through one unified component, reducing the need for separate sampling operations and minimizing contamination risks while maintaining ease of operation.
2Measurement precision
If multiple in-situ sensors are added to monitor metabolites, then real-time monitoring capability is improved, but device complexity increases
Solution Approach 1:
Multiple sensor ports and sampling ports are merged into a single integrated reactor head plate structure. This consolidation allows multiple sensors (pH, dissolved oxygen, glucose, lactate) to be mounted on one component rather than requiring separate mounting structures, thereby reducing overall device complexity while enabling comprehensive real-time monitoring of multiple metabolites.
3Loss of time
If in-situ glucose sensor is implemented, then analytical timelines are shortened, but sensor integration complexity increases
Solution Approach 1:
The reactor head plate is pre-designed with dedicated sensor ports and mounting structures during the manufacturing stage. This preliminary preparation of the mounting infrastructure eliminates the need for complex integration work when installing glucose sensors, allowing rapid sensor deployment and reducing analytical timelines without significantly increasing operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables real-time glucose monitoring, reducing contamination risks, lowering cell density and product yield issues, and allowing for earlier corrective measures, while maintaining transferability to large-scale processes.
Implementation Method 1
the glucose sensor is an electrochemical and/or enzyme-based sensor
Implementation Method 2
the pH sensor is a pH electrode
Data Source
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AI summary
Herein is reported a small volume bioreactor comprising a cultivation vessel and a reactor head plate, wherein the cultivation vessel has a working volume of from 20 ml to 350 ml and comprises two or more in-situ sensors, wherein the reactor head plate comprises an in-situ sensor port, wherein to the in-situ sensor port at least one in-situ glucose sensor and one in-situ pH sensor are connected.