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Sartorius bioreactors retrofit with flexible and plug and play control

Discover how we performed a Sartorius bioreactors retrofit using an open QB Control platform to eliminate vendor lock-in for advanced bioprocessing.

Industry

Pharma / Biotech

Scope

IT/OT Integration / Custom Control Software / Hardware Retrofitting / MTP Standard

Timeframe

3 months

Technology

  • QB Edge & QB Control
  • MTP Standard (NAMUR)
  • OPC UA & MQTT Protocols
  • Hamilton Sensors (pH/DO)
  • IOLAN Serial-to-Ethernet Servers
  • A4BEE MTP Library

40%

faster calibration

60%

reduction in manual data entry

3

months of complete transformation to an open platform

The client

A leading pharmaceutical producer and CDMO (Contract Development and Manufacturing Organization) develops and commercializes medicinal products and related healthcare solutions, combining research and development capabilities with manufacturing expertise. Its portfolio includes therapies used in long-term patient care as well as complementary products. The company operates modern manufacturing and quality control facilities, enabling processes that comply with regulatory requirements and GMP standards.

Business needs

The client needed to integrate laboratory bioreactors into a single, centralized control system to eliminate fragmented data silos. The requirement was to manage a diverse laboratory and production setup , consisting of four control towers for glass-vessel bioreactors (ranging from 1L to 5L) and a large-scale 70L stainless steel bioreactor tower. Beyond basic control, the goal was to extend the systems' capabilities by implementing advanced data acquisition, centralized recipe management, and sophisticated process analytics - features that surpassed the native functionality of the original Sartorius-based setup.

The challenge

  • 01

    Vendor Lock-in Dealing with closed PLC controllers where the original source code was inaccessible for modifications.

  • 02

    Rigid Hardware Working with proprietary hardware that offered no native options for reconfiguration or expansion.

  • 03

    System Interoperability Bridging the gap between legacy industrial PLC logic and the modern QB digital platform.

  • 04

    Sensor Standardization Harmonizing various proprietary sensor connectors and communication protocols into a unified interface.

Our solution

We started with the technical retrofit of the bioreactor control layer, replacing restrictive legacy hardware with an open, scalable architecture. To streamline operations, we implemented a centralized system where four control towers for glass-vessel bioreactors (1L–5L) and one 70L stainless steel bioreactor tower were all integrated into a single QB Edge gateway.

  1. PLC Modernization

    Replaced the existing, closed PLC controller with a new, open unit to allow for custom logic implementation with vendor agnostic approach.

  2. Edge Connectivity

    Integrated QB Edge to serve as the single gateway between the production floor and the digital platform for all connected units.

  3. Sensor Refurbishment

    Replaced Hamilton VP8 sensor connectors with standard M12 connectors and routed liquid level/foam sensors via relays to a new I/O coupler.

  4. Smart Device Networking

    Connected Hamilton measurement devices to an IOLAN server to enable network-based data access.

  5. MTP-Based Programming

    Quickly programmed the new PLC using A4BEE’s proprietary MTP library, ensuring the code is modular and future-proof.

  6. Advanced Process Logic

    Replicated and optimized Sartorius cascade regulator logic within MTP services for precise process supervision.

  7. Data Orchestration

    Configured a proprietary OPC UA connector for seamless data transmission via the MQTT protocol.

  8. QB Control Deployment

    Installed and configured QB Control on the Edge device, enabling centralized management of the bioreactor's pumps, pH, and DO sensor calibrations.

Technology used

  • QB Edge & QB Control
  • MTP Standard (NAMUR)
  • OPC UA & MQTT Protocols
  • Hamilton Sensors (pH/DO)
  • IOLAN Serial-to-Ethernet Servers
  • A4BEE MTP Library

The outcome

The implementation transformed the laboratory's capabilities, providing a unified and transparent environment for complex bioprocessing.

  • Centralized Supervision
  • Ownership of Logic
  • Enhanced Data Acquisition
  • Scalable Infrastructure
  • Cost Efficiency
  • Unrestricted Data Access

What we implemented

  • Controller Replacement Swapping proprietary PLCs for open-standard hardware to enable full access to the control logic.
  • Standardized Interfacing Converting proprietary Hamilton VP8 connectors to M12 to simplify maintenance and hardware replacement.
  • Service Configuration Implementing MTP services specifically designed for cascade regulation, ensuring stable and repeatable bioreactor environments.
  • Calibration Management Integrating automated calibration workflows for pumps and sensors directly into the QB Control interface.
Łukasz Paciorkowski
This bioreactor integration was about transforming a restricted 'black box' into a high-performance, open asset. By replacing the locked controllers, we successfully removed the vendor barriers that had been limiting the client’s operations. Implementing the QB Control platform and MTP standards gave them full ownership of their process logic, allowing them to scale their research independently, without being tied to a single provider’s roadmap.
Łukasz Paciorkowski — CEO

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