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Fully Automated Autosampling Control System

A4BEE closes the loop in bioprocessing. Automated, MTP-compliant sampling that eliminates manual errors. Gain real-time insights.

Industry

Biotech / Life Sciences / Industrial Automation

Scope

Closed-Loop Control / Autosampling Integration / MTP Standard / Process Analytics (PAT) / OT Architecture

Timeframe

12+ Months

Technology

  • Industrial Automation
  • MTP (Module Type Package)
  • Middleware Development
  • Process Analytical Technology (PAT)
  • Grafana
  • REST/gRPC APIs

100%

automated execution of the sampling sequence

0

Manual data entry required for sampling results

The client

A Global Life Sciences innovator working on a next-generation bioprocessing platform. Their goal is to eliminate manual interventions in drug production by creating a self-driving system where critical quality attributes (CQA) are measured and controlled automatically in real-time.

Business needs

The "Holy Grail" of modern bioprocessing is continuous, automated monitoring. The Client had a robust bioprocess controller and high-end analytical instruments, but they operated as separate silos. The missing link was the "Control Loop": manual bottlenecks, disconnected data, and integration barriers with third-party analytical devices.

The challenge

  • 01

    The "Black Box" Problem Integrating a closed third-party analytical unit that wasn't designed for external automated control.

  • 02

    Orchestration Logic Creating a failsafe sequence: Trigger Sampling -> Transport Fluid -> Analyze -> Write Data Back with millisecond precision.

  • 03

    Standardization (MTP) Ensuring future analyzers could be plugged in without rewriting code by using Module Type Package standards.

  • 04

    Data Correlation Merging high-frequency sensor data with low-frequency analytical data into one coherent dashboard.

Our solution

We engineered the Digital Handshake that bridged the gap between the bioreactor and the analytical lab. We built a fully automated Autosampling Control Loop. The solution entailed:

  1. Interface Engineering (The Translator)

    Reverse engineering of the device's API and development of a custom Middleware Driver to translate proprietary signals into industrial protocols.

  2. The Logic Engine (The Brain)

    Implementation of the Sampling Orchestration Logic and error-handling routines like "Sample Line Clogged" detection.

  3. Unified Visualization (The Eyes)

    Deployment of a Grafana-based PAT Dashboard, allowing operators to see analytical results plotted instantly alongside process parameters.

  4. Operational Stabilization

    Validated the loop through rigorous testing ("Runs Support") to ensure reliability over multi-week continuous processes.

Technology used

  • Industrial Automation
  • MTP (Module Type Package)
  • Middleware Development
  • Process Analytical Technology (PAT)
  • Grafana
  • REST/gRPC APIs

The outcome

The project resulted in a robust, scalable system that achieved a fully functional automated cycle of sampling, analysis, and data ingestion. By eliminating manual data entry, the solution ensured total data integrity and process transparency, while the MTP-compliant architecture provided a vendor-agnostic foundation for future scalability.

  • Automated Feedback Loop
  • Data Integrity
  • Vendor-Agnostic Design
  • Process Transparency

What we implemented

  • Mock-up Testing Developing "Virtual Analyzers" to stress-test the control logic safely before connecting physical hardware.
  • Alarm Management Configured specific alarms for the autosampling subsystem (e.g., "Reagent Low") to alert operators via the dashboard.
  • Zero Manual Entry 100% automated execution of the sampling sequence and real-time availability of CQA data.
  • MTP Compliance Implementation of Module Type Package standards for modular, interoperable lab automation.
Karol Doroszewski
We turned a disconnected lab bench into a cohesive organism. By closing the control loop between the bioreactor and the autosampler, we moved far beyond simple time-saving and enabled true real-time feedback control. The system now 'knows' the state of the culture instantly, without a human ever touching a pipette.
Karol Doroszewski — R&D Lead Engineer

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