Analytical Sensors for Bioreactors

Accurate Process Control in Fermentation & Cell Culture

From R&D to cGMP production, METTLER TOLEDO offers a scalable solution for analytical measurement in bioreactors. With a portfolio that includes sensors for pH, ORP/redox, dissolved CO2 and dissolved oxygen, METTLER TOLEDO provides the comprehensive set of measurements required for accurate process control in bioreactors. These sensors are hygienically designed and can be implemented in conventional bioreactors or single-use bioreactor bags at any scale.

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What analytical sensors are critical in a bioreactor?

Several process variables are important to monitor in a bioreactor, regardless of the size. METTLER TOLEDO recommends pH, ORP/redox, dissolved oxygen, dCO2 and optical density sensors as critical measurements in bioreactors. 

How do analytical sensors help to ensure batch-to-batch consistency?

Batch-to-batch consistency is the central aim in antibody and protein therapeutics manufacturing, and METTLER TOLEDO measurement solutions are designed to enable it. High accuracy post-sterilization and a robust construction of sensors, in combination with sanitary process connectors and housing help to eliminate analytical variability batch after batch.

Are different sensors needed for perfusion bioreactors versus a batch or a fed-batch?

In general, no. The cells growing in culture do not know or understand the difference between model of culture or sensors in the process. What is important is to implement similar analytical measurements from the bench to the manufacturing floor, providing the same accurate measurement of the pH, ORP, dissolved oxygen and dissolved CO2 in culture media. This enables a user to be able to make adjustments accordingly to optimize productivity, growth rate and yield of a batch.

What are the benefits of digital ISM sensors in bioreactors?

Intelligent Sensor Management, or simply ISM®, is a digital technology for inline process analytical systems that simplifies sensor handling, enhances measurement integrity and reduces sensor lifecycle costs. These benefits translate into substantial gains for pharmaceutical companies in relation to production process reliability, data transparency and managing regulatory compliance. METTLER TOLEDO produces ISM pH sensors, ISM DO sensors and ISM CO2 sensors for bioreactors.

Are different sensors needed for conventional stainless steel bioreactors versus single-use bioreactors?

This is very dependent on your operational set-up and the type of bioreactor considered. Conventional, reusable sensors that can be used in stainless steel, rigid wall bioreactors can be implemented in single-use bioreactor bags with the right single-use housing and connectors. Using an ISM sensor in this case can help you to understand the remaining life of the sensor for long batch processes, and to understand whether the sensor should be decommissioned. Singe-use sensors can also be directly welded into the bioreactor bag. This is done by the bag manufacturer. METTLER TOLEDO works with global bag manufacturers to provide single-use sensors that integrate into their systems. These are built on the same measurement technology as METTLER TOLEDO's conventional, reusable sensors.