Single-Use Sensors for Bioprocess Applications

Downstream processing typically refers to the post-harvest processing of the clarified production media. These downstream process steps include capture/recovery of the desired biologic, viral inactivation, concentration and purification, final formulation, and final filling of vials for packaging and distribution.

Upstream processing typically refers to the production of biologics using bioprocesses such as large-scale cell culture or fermentation. Upstream processing begins with the preparation and inoculation of the smallest bioreactor in the seed train of bioreactors that eventually seed the final production bioreactor. For example, the first bioreactor in the seed train is typically in the 2 to 10-liter range, while the final production bioreactor is often in the 1000 to 4000-liter range. Each step in the seed train is typically a 4x to 5x scale-up. A 10-liter bioreactor may be used to seed a 50-liter bioreactor which, in turn, can seed a 250-liter bioreactor. The 250-liter bioreactor can then seed a 1000-liter bioreactor which, in turn, can seed a 4000-liter bioreactor. Typically, upstream processing includes the harvest of the final production vessel as well as the initial clarification of the harvested media that contains the desired biologic.

A single-use sensor is typically shipped gamma sterilized and ready to use, eliminating the costly and time-consuming cleaning, maintenance, and operator installation required for reusable sensors. Single-use sensors reduce downtime between batches while providing process measurement and control as good or better than traditional autoclavable and sterilizable sensors.

SingleSense^® single-use sensors are available to measure critical process parameters, such as temperature, pH, dissolved oxygen (DO), and pressure, that are essential for monitoring and controlling bioprocesses such as large-scale cell culture and fermentation.

Single-use sensors are designed to be ready to use, easy to install, and adaptable to different process configurations, making them suitable for bioprocessing applications, from lab-scale to commercial production.

SingleSense^® single-use sensors from Broadley-James are designed for preinstallation and one-time use in upstream and downstream bioprocess applications, including media mixing, buffer prep, and large-scale cell culture. These single-use sensors can be preinstalled into any bioprocessing container or downstream tubing assembly and streamline pH, DO, and pCO2 measurements. Broadley-James single-use sensors are rugged, ready to use without preconditioning, and have a 30-month shelf life.