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Cell culture media is a key component of upstream bioprocessing needed to encourage the growth and survival of cells. This is vital to achieving a viable cell density and, ultimately, the desired product titre. However, its filtration can be a challenge for biopharmaceutical manufacturers.
Cell culture media is a complex mixture and typically contains up to 60 ingredients. However, the exact composition will differ based on the media chosen for the specific application.
Media is usually supplied either as a powder, concentrate or working solution. If a powdered media is used, it must be mixed and sterilized on site prior to use.
Cell culture media can be categorized into several different formats based on its composition:
Serum
Serum is a nutritionally and protein-rich substance derived from animal blood. Serum containing media was once seen as essential for good cell growth and proliferation, however, the desire for animal component-free media due to concerns about contamination and regulation have led bioprocesses away from this media type.
Serum is also expensive and as it is a natural product, it is by nature uncharacterized and is prone to a high degree of variation.
Serum-free media
Serum-free media often contains proteins/protein hydrosolates and, while it is more characterized than serum-based media, it may still contain components derived from animal sources.
Animal-derived component-free media
Animal-derived component-free media offers an alternative to serum media. It uses non-animal derived proteins and hydrololates available from soy, yeast or other non-animal-based sources.
Protein-free media
Protein-free media allows greater chemical definition of the media's make up.
Chemically defined media
Chemically defined media aims to eliminate variation by using only fully defined components - these may be animal-derived or animal-free depending on the media.
Whichever media is used, a compromise must be found between safety, characterization and performance. Robust supplier quality assurance is needed to ensure traceability and the procurement of contamination-free media.
The media will ultimately be chosen to suit the process.
So, what is cell culture media composed of?
Depending on how characterized the media is, the concentrations of components and exact composition may vary lot-to-lot. Different medias will also have different compositions.
The ingredients in cell culture media provide a rich nurturing environment for the cells biopharmaceutical manufacturers wish to propagate. Unfortunately, that kind of environment is a place in which bacteria or other unwanted microorganisms can flourish.
The role of filtration
Filtration is commonly used to protect cell culture media from contamination. If the powdered media is prepared on site, it will be prepared in a mixing vessel. Components such as water will be filtered to remove contamination prior to entering the vessel and any air and gas or venting will be protected using gas filters.
Prior to entering the bioreactor itself, the media will be filtered to ensure its sterility - and to, therefore, protect the bioreactor. This filtration may involve prefiltration as well as sterilizing-grade filtration or Mycoplasama removal filtration, depending on the process.
0.2 micron rated validated sterilizing-grade filtration is used to achieve sterility, or if Mycoplasma contamination is of concern. 0.1 micron rated filtration validated for Mycoplasma removal should be used. Depending of the process and media, prefiltration may also be required.
The correct design of this filtration system is crucial in optimizing the process. The design must take into account:
The challenges of cell culture media filtration
A number of issues can arise in the cell culture media filtration process:
However, these issues can be mitigated by optimizing the filtration system correctly.
Parker supports biopharmaceutical manufacturers in filtration system optimization through testing, process trials and validation as well as technical support for existing systems. We have an extensive range of filters designed for cell culture media filtration including PROPOR SG, our standard 0.2 micron sterilizing grade product, PROPOR HC, our high capacity sterilizing grade product for difficult to filter or variable medias and PROPOR MR 0.1 micron filter designed for use in processes where Mycoplasma contamination is a concern.
For more information on cell culture media filtration, view our recent webinar: Optimization of Cell Culture Media Filtration in Bioprocessing
What are your biggest challenges in sterilizing filtration media? Let us know in the comments below.
This post was contributed by David Heaney, market development manager, Parker Bioscience Filtration, UK
Parker Bioscience Filtration specializes in automating and controlling bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively ensuring the quality of the final product. Visit www.parker.com/bioscience to find out more.
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The microbial stabilization of beer is of critical importance for the shelf-life of beers – and as beers are exported all over the world, it’s vital that their original characteristics still remain intact when they arrive in the glasses of thirsty consumers in faraway markets.
An increasing number of brewers are turning to sterile filtration as a reliable method to ensure a longer shelf-life of their packaged beer. Indeed, many brewery operations have been moving away from flash pasteurization – the traditional method of removing spoilage organisms – due to its negative impact on the flavour profile of the end product and the many advantages offered by sterile filtration.
Filtered beer retains unique and desirable characteristics
It has been shown that beer which has been filtered to achieve stabilization retains its unique and desirable characteristics more efficiently than beer stabilized through flash pasteurization: the sterile filtration process is gentler, compared to the harsh process of flash pasteurization. Sterile filtration can also have a beneficial effect on taste characteristics throughout the duration of the beer’s shelf-life.
And there are more advantages too.
Partnerships deliver a better product
Parker Bioscience has built a partnership with Agidens Process Automation that combines more than 50 years of brewing filtration experience and industry-leading products to deliver a better beverage. Starting with Parker Bioscience Filtration's detailed knowledge and experience of brewing processes and automation, Parker offers cutting-edge technology for use in sterile filtration. Using this technology, Agidens is now offering a platform of sterile filtration/cold stabilization modules to suit a range of beer flow capacities and specifications, as a more efficient alternative to pasteurization.
Sterile filtration in practice – Zagrebačka pivovara installationThe combined experience of Agidens Process Automation and Parker Bioscience Filtration was recently brought to bear for Zagrebačka pivovara in Croatia, which is part of Molson Coors. Zagrebačka pivovara wanted to expand its range with a premium, non-pasteurized lager and needed to work with a provider with proven expertise in cold stabilization technology.
It commissioned Agidens to implement a Cold Stabilization Module (CSM) at its brewery site in Zagreb, Croatia. In just five months, Agidens’ engineering team was able to provide a tailor-made CSM solution that was integrated into the brewery’s existing production line.
The CSM installation consists of three modules for a total length of 6.75 metres:
The site was only accessible via a small elevator which meant that the CSM had to be custom-designed, disassembled and transported before it could be re-built and installed on site.
The CSM installed at the Zagrebačka pivovara site filters an average of 250 hectolitres of beer per hour.
The CSM uses Parker Bioscience Filtration’s PREPOR NG and BEVPOR BR filters in a combination to achieve microbial stability whilst protecting the taste characteristics of the premium lager.
The BEVPOR BR range of filters is constructed with a unique Polyethersulphone (PES) membrane, offering a long service life and therefore a highly efficient solution with a low cost of operation in sterile filtration of beer applications.
Parker Bioscience Filtration’s PREPOR NG filters have been specifically developed to remove yeast and particulate such as filter aids and haze components. The superior level of retention ensures that a consistent quality of the brew is delivered and provides a greater level of membrane filter protection during cold stabilization.
This post was contributed by Lee Pattison, Food and Beverage Product Manager, Parker Bioscience Filtration, United Kingdom.
Parker Bioscience Filtration offers filtration solutions to protect the quality and taste of beverage products. By working with our application experts, manufacturers can develop a tailored solution to ensure their beverage is free from contamination, full of flavour and visibly clear.
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With six decades of experience and hard-earned know-how, Bob Brooks is an expert in residential and commercial site preparation. He began operating equipment at just 14 years old and for the past 40 years he has owned his own business. He has customers throughout the Puget Sound and keeps his calendar full through strictly word-of-mouth promotions. Over the course of his 60-year career, he has utilized a wide variety of attachments — and nothing he has used compares to Parker’s Helac PowerGrip® Multi-Purpose Jaw Bucket in regards to productivity.
At current fuel prices, saving 1/2 gallon per hour adds up to more than $2,000 saved every 1,000 machine hours. Their transportation costs of moving machines between job sites have also decreased by shaving 12,000 pounds off of B and B Excavating’s payload.
PowerGrip outperforms the competition
Brooks is admittedly tough on his PowerGrip. The sites he clears in the lush Pacific Northwest climate are full of fast-growing evergreen trees, glacial till and more. B and B Excavating previously used cylinder-style jaw buckets and found that they were frequently damaging cylinder-rods and plates when working in rocky soil or digging out concrete foundations. Brooks also disliked the cylinder-style jaw bucket's wasted space in the bucket — with the mounting cross tube on the jaw frequently in his way. With PowerGrip, all the moving parts are fully-enclosed and there are no obstructions in the bucket shell.
While using a thumb combination he grew frustrated by the weight penalty at the end of the boom. B and B Excavating also suffered from inefficiencies like having to take the time to get the bucket under a stump and then
pinning the stump with the thumb before working it out of the ground. When grabbing material with PowerGrip, Brooks could just drop down on the object with an open jaw, close the jaw and remove the object. ‘‘PowerGrip offers more control over picking and placing material than anything I have used," said Brooks.
Brooks also values PowerGrip’s ability to seamlessly switch between tasks on the job site. "The PowerGrip really impressed me with its versatility. One minute I am moving heavy boulders or taking down a tree — the very next minute I am grabbing and loading old brittle concrete without breaking it,” explained Brooks.
A powerful and durable solution
PowerGrip is equipped with a durable, enclosed rotary actuator hinge that's ideally suited for the toughest conditions. Parker’s Helac rotary actuator hinge technology offers 120 degrees of smooth jaw movement and constant clamping force. The jaw rotation is generated by the massive rotating pivot point between the jaw and back of bucket that’s designed with the Helac sliding-spline operating technology, which converts linear piston motion into powerful shaft rotation. The end caps, seals and bearings work in unison to keep debris and contaminants out of the inner workings of the actuator, prolonging life and reducing required maintenance. High strength, abrasion resistant steel is used throughout for added durability.
PowerGrip buckets are available for equipment between the 4-20 tons class, with bucket width ranges from 24 inches to 48 inches in the trenching and excavating profiles and 48 inches or 60 inches in ditching and grading profiles.
The PowerGrip really impressed me with its versatility. One minute I am moving heavy boulders or taking down a tree — the very next minute I am grabbing and loading old brittle concrete without breaking it,” according to Brooks. “I’ve used a lot of different hydraulic thumbs and cylinder-style jaw buckets in the past, but to me, nothing on the market compares to the versatility and productivity of the PowerGripl/Multi-Purpose Jaw Bucket.
-Bob Brooks, owner, B & B Excavating
Download the brochure for more information on PowerGrip.
This article was contributed by Jessica Howisey, marketing communications manager, Helac Business Unit, Cylinder Division
.
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For power plants located in moisture-rich environments, such as coastal locations, high levels of humidity, rain, fog, mist and sand can damage and impair the performance of the gas turbine. Coalescers are installed to remove moisture and liquid phase corrosives from the airstream — protecting the downstream filters and the turbine. In this blog, we will look at the coalescing process, issues with today's coalescers, and explore the effectiveness of a new coalescer technology.
How coalescing works
Coalescers remove moisture by agglomerating water droplets, making them larger and heavier. This allows a large proportion of the droplets to drain away rather than continue in the airstream, which helps avoid these two problems:
1. Small liquid droplets allowed to travel downstream can become embedded between the pleats of the filter (pleated filters are the current standard design for high-efficiency filter products). This impediment to the air can lead to differential pressure spikes. This can lead to an accelerated differential pressure increase in certain conditions such as fog, causing gas turbine alarm and trip levels to be reached quickly.
2. Small liquid droplets can also form mud caused by:
In either case—and especially with mud—it is common to see a differential pressure spike.
Is compressed air pulsing effective?
Unfortunately, the use of a compressed air pulsing system has a limited effect. The system would have to exceed normal operating limits to obtain the inertial forces required to overcome the surface and frictional effects present and adequately remove the embedded liquid and/or sticky dust.
Historically, coalescer media has been similar to what is used in dust filtration. Thus, they naturally capture dust in addition to liquid, which can result in block up, differential pressure increase and, in high-dust environments, three other problems:
For example, in a typical, self-cleaning filter house, the high-efficiency cartridge filters are protected from the elements by weather hoods. (see figure to the left). This arrangement provides basic protection only against big, heavy rain droplets. It does not protect filters against exposure to fine and light fog droplets. Exposure of the filter elements to fine water particles in the form of fog leads to wet filters and reduced filter life, manifested as high differential pressure across the filters and/or the gas turbine alarm being reached. If the high-efficiency filter is not hydrophobic (not moisture repellent), moisture droplets (potentially containing salts) will leach through the filters resulting in:
Coalescers on the market today exhibit problems such as:
New filtration technology offers a solution
Whether the trouble stems from dust, fog or sand, power plants operating in harsh environments need an effective solution with coalescers to protect both the life of the high-efficiency filters and the performance of the gas turbine. The clearcurrent TS1000 coalescer panel filter from Parker, for example, uses a new technology to provide fine mist/fog removal effectiveness combined with significantly low dust removal efficiency.
Unlike traditional coalescers, the TS1000 coalescer panel uses 100 percent synthetic high-performance woven mesh that catches small liquid droplets, combines them with larger ones, then drops them out of the airstream while allowing bypass of sand and dust particles.
“The clearcurrent TS1000 has excellent fine mist/fog removal effectiveness with significantly low dust removal efficiency ... It provides superb performance during the fog season with low risk of clogging during a sand storm. In the end, it requires much less attention from the operator and helps reduce the maintenance to a minimum.”
— Tim Nicholas, powergen market manager, Parker Hannifin
Other features and benefits include:
Three comprehensive field tests were conducted to demonstrate the effectiveness of the TS1000 over competitive coalescers. The results showed the clearcurrent TS1000 coalescer panel filter went about three times longer than other products tested before needing to be cleaned, and when it did need cleaning, the work was quicker and extended the life of the coalescer for up to 12 months.
Key takeaway
The clearcurrent TS1000 coalescer panel filter helps maintain gas turbine inlet air quality, whether the harsh environment produces dust, fog or sand. Not only does it improve the overall coalescing performance, but it also delivers low pressure drop, requires low maintenance and extends service life to achieve better gas turbine operation.
This post was contributed by Tim Nicholas, powergen market manager, Parker Gas Turbine Filtration Division.
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Chiller or water cooling systems are used for temperature control in many applications, from industrial manufacturing to food and beverage to commercial applications for hospitals and medical. In many cases, the integrity of the final product and the process itself are reliant on precise heat management to ensure quality as well as safe, efficient and reliable operation. Operations managers and engineers will select and install a process chiller system for precision cooling of low viscosity and industrial cooling fluids.
Featuring a unique design, Parker's range of Hyperchill water chillers provide precise and highly accurate temperature control of cooling fluids (water, water-glycol mixture, low viscosity fluids). High-quality components in the hydraulic and refrigerant circuits ensure continuous operation and deliver energy efficiency, even at partial loads, resulting in cost savings and carbon footprint reduction for an improved environment.
When designing a cooling system, a number of variables must be evaluated. The chiller location, positioning and distance from the application are important considerations. The application type and the number of chillers needed to serve a process also have a bearing on the system design.
Parker's engineers share the following key points that facilities managers should consider for the successful installation and performance of a chiller and cooling system:
Chiller location and positioning
The location and positioning of the chiller is critical for achieving and maintaining the correct cooling performance. In general, most of the chiller range can be located both internally or externally. Parker's Hyperchill and Hyperchill Plus range of precision water chillers offer a robust and reliable cooling solution whether internal or external locations. Reviewing rating is part of our recommended guidelines:
Internal installationChiller models ICEP002, ICEP003 & ICEP005 have an Ingress Protection (IP) rating of 33 and must be located and installed internally.
Hyperchill Plus models from ICEP007 and above possess an IP54 rating and are suitable for installation both internally and externally. This is also the case for the Hyperchill product range.
Ventilation around the chiller is essential for maintaining system performance. The fundamental purpose of the chiller is to remove a heat load from the water circuit to the local atmosphere. If the local environment is inadequately ventilated, heat will build up in the circuit and the chiller will sound an alarm. Consider the following:
Frost protection
Exposing a water-cooled system to low temperatures can result in frost damage to the chiller and water circuit. Frost protection should be considered in the following circumstances:
1. Include the antifreeze heating option in the chiller specification.
2. Addition of antifreeze (ethylene glycol) solution to the cooling water.
In instances where a chilled water temperature of < 7oC (45oF) is required, an antifreeze solution must be added to the cooling process water.
The table below provides guidance on the glycol % required to meet specific outlet water temperatures:
When using ethylene glycol in the chilled water system, it is important to consider these 6 key factors:
When designing the complete chilled water circuit, these points should be followed:
The appropriate water fill kit should be selected based on the chiller installation requirements. The following options are available:
This option allows for the installation of the chiller in a closed water circuit. The kit contains an expansion vessel, pressure relief valve, pressure reducing valve, pressure gauge and drain ***.
The chiller can be configured with the water fill kit already installed. Alternatively, the kit can be supplied separately to the chiller.
NOTE: After commissioning, the main water supply can be isolated locally.
Ambient water fill kit
The ambient water fill kit can be used in open water circuit systems. The fill options are:
Electrical work should be undertaken by a qualified technician. Please review the manual prior to completing the electrical commissioning of the chiller and follow these guidelines:
The Hyperchill range has the option to include remote control. The chiller can be controlled remotely through two control levels:
Base level controlPlease consult the operation and maintenance guide and follow the appropriate steps. Fundamental checks include:
Conclusion
Parker Hyperchill water chillers maintain maximum quality and cleanliness of the cooling fluid, resulting in improved process efficiency and productivity as well as reduced maintenance costs and downtime. Following the above recommendations from Parker's engineers will ensure the successful installation and performance of a Hyperchill water cooling system.
Parker Purpose
After more than a century of experience serving our customers, Parker is often called to the table for the collaborations that help to solve the most complex engineering challenges. We help them bring their ideas to light. We are a trusted partner, working alongside our customers to enable technology breakthroughs that change the world for the better.
This post was contributed by James Brown, compressed air and gas treatment/analytical gas sales manager and Filippo Turra, product manager, Parker Gas Separation and Filtration Division EMEA
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Single-use technology has major benefits for the biopharmaceutical manufacturing industry. It enables rapid turnaround times between batches and allows facilities to be multi-product while driving down the cost of goods.
This, in turn, enables more people to access life-saving medicines.
But the use of single-use technology can be greatly enhanced by automating single-use processes, with data acquisition, process monitoring and control, and batch record generation all possible. This allows more complex unit operations to be run in cGMP compliant production environments.
Here we look more closely at the benefits of automating single-use for normal flow filtration (NFF) and tangential flow filtration (TFF)
Automation for NFF
For operators that remember the early days of single-use technology, turning down a pump speed when a line started to balloon due to pressure build-up may have been a very familiar exercise. Manual interventions in single-use platforms handling NFF were common.
Then came the first step in automating single-use processes. a pressure sensor linked to a display, which enabled the pressure to be read from a monitor. Although this still required attention to be paid to the system, it did free up operators from being "pump watchers".
The next step was linking this to an alarm to alert the operator — further freeing up the operator but requiring them to be local — and the next level of automation applied would monitor the dP and then switch off the pump once a trigger point had been reached, again freeing up the operator but not adding real value to the process.
Through Parker's SciLog® technology, we can apply the R/P stat method, which brings the full benefits of automation to NFF.
The R/P Stat method
R/P Stat is an automated method for controlling NFF that can also improve filter capacity by up to 30 percent.
It works by controlling the pump speed based on the measurement of the pressure across the membrane (dP). The process starts running at a set speed and pressure in monitored.
As the pressure builds up over time, instead of reaching a trigger point for pressure and switching the pump off, the pump speed is reduced to prevent the dP building to a point that would trigger a process stop.
By running in this fashion, the process can run for longer.
So, what are the advantages of R/P Stat?
Firstly, a smaller filter can potentially be used as the safety margin on the surface area need not be as great.
Secondly, the R/P Stat method makes it easier to handle unpredictable feed streams, for example, harvesting cell cultures in process development laboratories where the cell density, cell viability and productivity can vary widely from batch to batch.
Automation for TFF
In a more complex operation like TFF, a number of inputs need to be monitored and controlled and there are a range of outputs that could trigger the endpoint.
Monitored functions
Outputs for process endpoints
The volume of mass related process endpoints is relatively easy to control, based on measurements from a load cell. Through monitoring a change in the volume by measuring weight, process decisions can be made.
Obtaining a particular mass in the retentate tank during a concentration step would indicate that a certain concentration factor has been reached.
Alternatively, during a diafiltration step, reaching a set point on the permeate side would indicate that the required number of diavolumes have been processed.
Process decisions involving pressure are more complex as pressure is a function of the pump speed and pressure control valves. However, through automation, this balance can be achieved, for example, to maintain a set dP or TMP in the process.
The system will open and close valves and increase or decrease pump speed based on the programming logic to maintain the required set points, usually pressure, but also maintain the required process conditions, such as cross flow rates in a TFF filtration device.
Data acquisition
It would be impossible to manually take a reading from three pressure sensors, two pumps and a couple of balances ever second over a four-hour period while at the same time calculating dP and/or TMP then adjusting the system to maintain a set point. Automation, however, makes this level of data capture and process control possible.
In addition, another advantage of an automated process is the generation of a data set that captures all the outputs from sensors, pumps and balances which is unambiguous, has the capacity to be copied without error, can be stored in multiple places, has an audit trail of changes, and can be downloaded easily for analysis without error. All of these are essential for bioproduction.
Read the full white paper - Automation in Single-Use: Unlocking the True Potential of Single-Use Technology
This post was contributed by Guy Matthews, division marketing manager at Parker Bioscience Filtration, United Kingdom.
Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product.
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Every day HVAC technicians help keep people comfortable by installing and servicing HVAC systems. HVAC technicians also play an integral role in improving the quality of indoor air by regularly changing the air filters designed to trap microbial contaminants such as mold, bacteria, and viruses along with allergens that can induce mild to serious health effects. Even before the COVID-19 pandemic, it was wise to assume these air filters contain living pathogens since the highest-efficiency rated types do not actively kill organisms.
The current pandemic has raised awareness and questions centered around best practices to follow for air filter replacement. There are a number of recommendations that can be taken to help keep technicians safe while preventing the spread of dangerous airborne pathogens. Here are some recommended steps to replace an air filter:
To maintain healthy breathable indoor air, standard HVAC air filters should be changed at least every three months, or at the minimum recommendation of the air handler manufacturer. In some situations, the filter may need to be changed more frequently. Changing an air filter on a regular maintenance schedule also keeps HVAC equipment in top working condition, prevents breakdowns, reduces energy consumption, and limits expensive repairs.
There are HVAC air filters that are specifically made to capture smaller particles like viruses. When considering a filter upgrade for better particle capture, Parker suggests a minimum efficiency reporting value (MERV) rating of 13 to 16. High-efficiency filters can affect the performance of an HVAC system so it’s best to check with a professional contractor or the system manufacturer when upgrading a filter.
To read more about recommended air filter replacement practices, download Parker’s latest bulletin.
This post was contributed by the HVAC Filtration Team.
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One of the most exciting advancements in the tech world happening today is not a new technology at all. Rather, it is the unique application of something that has dominated and excited the gaming industry since the mid-90s—virtual reality (VR). VR augments computer modeling by allowing engineers and designers to interact more intuitively with their designs.
The ability to delve into a new dimension has allowed technical designers to go from using a 2D computer screen to utilizing an immersive, 1:1 scale environment where designs can be experienced in their full capacity. In the analysis-design-build cycle, VR grants access to in-depth insights that detect design problems of a product before the first prototype is built for testing.
Another unexpected benefit of VR is that engineering teams can meet within the same virtual environment to evaluate a design when team members are continents apart. This saves time and money while taking team collaboration to the next level.
VR is an emerging technology that is improving at a rapid pace. With its use, comes the reduction of product design and analysis time. Integrating VR technology into factories and design flow allows manufacturers around the world to simplify processes, reduce costs, and improve safety.
How Different Companies are Using VR to Change the Way They Operate
Industrial manufacturing firm, Parker Hannifin, has been at the forefront of using VR to create proprietary manufacturing processes. More specifically, their Parker Filtration Innovation Center outside of Nashville is using VR paired with automation and robotics to dramatically innovate manufacturing processes in filtration.
The Innovation Center houses the research and development for all Parker Hannifin Filtration products. Parker has dedicated 82,000 square feet of space solely to the development of new filtration technologies and proprietary manufacturing processes — this is the largest in the nation. A dedicated team of engineers, PhD scientists, U.S. military veterans, and industry experts have helped Parker secure over 500 U.S. patents and 1,200 global patents in the filtration focus.
The simulation group at the Innovation Center has taken advantage of VR to visualize computational fluid dynamics and finite element simulation results. Using VR to visualize the complex flows of filter elements has granted simulation engineers the freedom to explore the intricacies of air streamlines that curve and swirl within filter housings, providing an enhanced understanding of flow paths and reducing simulation analysis time.
"Parker’s Filtration Group has both the application expertise of filtration and the same skills and tools used in the aerospace industry to leverage advanced design modeling of our filtration systems. These tools help us design more efficient systems and accelerate time to market for new products by reducing time-consuming empirical testing because we’ve used computer models to get closer to final design before we even build the first prototype."
— Sucharitha Rajendran, Ph.D., modeling and simulation engineer, Parker Filtration Innovation Center
Another industry leader using VR is the Ford Motor Company. VR allows the company to optimize a vehicle’s design before a physical prototype is built. The Ford Immersive Vehicle Environment system creates virtual street environments in which automobile prototypes can be evaluated on aesthetics, ergonomics, and safety.
Using virtual technologies delivers significant savings and improvements in the areas of cost, time, and quality. It’s only a matter of time before industrial manufacturers see the considerable competitive advantages the technology can bring when leveraged strategically within operations. To fully leverage the technology, there needs to be a deep understanding of how to link the different components of the operation. The ability to use virtual technologies to create the link can help a company stand out against competitors.
Enhancing Automation and Robotics with VR
Automation has been commonly used in manufacturing since the 1970s. As robotics started to gain popularity, it was used to enhance the automation process. A successful automation strategy requires excellent decision-making on many levels. The strategy to link automation and robotics must align with business and operational goals. Now that VR is becoming a more affordable technology, the strategy should be to focus on integrating it into the automation process.
Engineers at Parker Hannifin have developed systems that take advantage of VR early in the life cycle of product development. For example, VR can be used to explore the layouts of new pieces of filtration equipment in plants to optimize space, ergonomics, and operator safety. Since these layouts are virtual, the engineers have the freedom to explore multiple layout options that would have previously been too costly and time-consuming to implement and test.
Engineers are also able to leverage VR to determine manufacturing line workflows to optimize robotic arm movements, placement of assembly parts, and safe locations for operators. Virtual robotic equipment can be implemented into manufacturing lines with ease within the virtual environment to optimize robotic arm motions, taking into consideration any obstacles in the plant and/or human operator zones.
Once optimized, these same virtual manufacturing lines can be used as a training aid for new operators who can be immersed in virtual facilities and be trained to operate a manufacturing line before they are even on the manufacturing floor, improving productivity and safety of the operator as they train in a safe off-line environment. The capability of creating a virtual automated facility to analyze workflows and layouts before raw materials are purchased, helps engineers design correctly the first time, avoiding reworks, reducing costs and time, and improving plant safety.
The Future of VR
While VR continues to make a big impact across many industries, the possibilities of improving the technology, its use, and expanding across even more industries are countless. For those already taking advantage of the technology, the benefits will grow exponentially. Further improvements to the functionality of VR will help increase productivity, improve efficiencies, and save time and money for those utilizing it in its current state. Even though the technology is constantly changing and improving, introducing VR now will help your company gain an advantage over competitors that may still be rooted in traditional manufacturing methods.
To learn more about how Parker is using advanced design and computer modeling to provide customers with more efficient systems in a quicker timeframe, watch this video:
Leading with purpose
Parker is dedicated to constantly innovating filtration technologies that not only improve the lifespan of our customers' equipment, but also aim to make a real difference in the communities that we live in and for our world by protecting and purifying for our customers' toughest applications with diverse solutions. Learn more about Parker Purpose
For more information on how Parker is leveraging virtual reality, visit our website.
This article was contributed by Simon Padron, mechanical engineer, Filtration Innovation Center, Parker Hannifin and Jennifer Kirallah, group demand generation manager, Parker Hannifin.
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Thanks to a unique design and advanced energy-saving technology, NITROSource nitrogen gas generators use less compressed air to generate more nitrogen than any other N2 generator currently available.
With benefits like substantially lower servicing costs, reduced downtime and longer working life compared to other gas generators, NITROSource offers the most cost-efficient nitrogen supply available — significantly more affordable and safer than traditional delivery methods such as gas cylinders and mini-bulk storage tanks.
NITROSource is food and pharmaceutical safe, in line with European statute (EIGA) and the USA Food & Drugs Administration (FDA Article 21) and Pharmacopeia compliant.
Key features
• Energy-saving technology - matches compressed air flow to the nitrogen outlet flow, resulting in less compressed air use, lower energy consumption and reduced operational costs.
• Low-cost maintenance, extensive working life - the carbon molecular sieve, the engine of the generator, delivers nitrogen more efficiently, leading to a very long working life – and major savings on maintenance.
• Five-year extended warranty available - offers the assurance of no unexpected maintenance costs and maximized factory up-time.*
• Provides nitrogen gas of 95% to 99,9995% equivalent nitrogen purity.
• Unique gas quality control system.
• Remote monitoring - enables connection to proprietary remote management and the generator control systems to control and track gas parameters from a central location.
• Easily upgradable supply - simply add extra generators as the application requirement grows.
Appropriate for manufacturers and producers in a wide range of industries
• Food production, processing, storage and packaging - snacks, dairy, grated cheese, milk powder coffee, edible oils.
• Beverage and bottling.
• Pharmaceuticals - primary and secondary manufacturing, centralized laboratory, inert storage and packaging.
• Materials processing - laser cutting, heat treatment and composite manufacturing.
• Electronics.
From food and beverage to materials processing to pharmaceutical, NITROSource advanced technology nitrogen generator delivers industry-leading performance resulting in increased productivity, sustainability and profitability for manufacturers and producers.
Watch this video and learn more.
*Subject to terms and conditions. Please contact your local authorized Parker distributor.
This blog was contributed by Phil Green, market development manager, Parker Gas Separation and Filtration Division, EMEA.
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As the benefits of single-use became clear and the technology became established in the 2000s, there was a drive to utilize it in more process steps. Single-use was being utilized in steps where process data would normally form part of the batch record, but as these assemblies had no automation or data capture capabilities, this information was either missing or manually recorded.
These process steps - including clarification, tangential flow filtration (TFF) and virus filtration - required complex monitoring and control as well as data acquisition. Only by automating the equipment could these systems operate, protect the process and collect and store the data in a way that was cGMP compliant.
There are a number of reasons. But perhaps it has more to do with perception than reality.
In a survey conducted during a Parker webinar entitled Single-Use Technologies, What is Next? the audience was asked: What would restrict you from implementing automation in your single-use process?
Nearly 20 percent of respondents said that their process didn't require automation.
However, it can be argued that all processes could benefit from some form of automation. It can enhance safety, improve process efficiency and release operators from some time-consuming, manual tasks, enabling them to carry out more value-added activities.
Just over 15 percent of respondents were concerned about the accuracy of sensors.
There are, however, highly accurate sensors available. For instance, Parker Bioscience Filtration's SciLog® SciPres single-use in-line pressure sensors achieve sensor accuracy of +/- 0.02 bar.
Almost 50 percent of respondents said they were concerned about cost.
Of course, there is a cost associated with putting an automated system in place, but this can also be regarded as an investment. The benefits relating to time-saving, complexity reduction, improved process security and predictability, and standardized training can all add up to a rapid return on investment for biopharmaceutical manufacturers.
Breaking down the barriers - how and why automation can help the biopharmaceutical industry
As detailed above, many of the perceived hurdles to implementing automation can be overcome.
A number of key drivers in the biopharmaceutical industry can be addressed by implementing automation in single-use processes.
Increasing speed to market
If the same technology on the same automation platform has been used during the development process as will be used at production scale, the scale-up will be easier to complete and more predictable when compared to a process that uses multiple automation platforms.
In addition, technical transfers can be made easier through single-use automation because a number of variables from the process can be eliminated through operators having access to the same equipment utilizing the same control systems. If consistent product contact materials are also used, extractables and leachables data are simplified, all of which again helps to increase speed to market.
Plus, an automated single-use system can be ordered, shipped and validated far more quickly than its stainless steel equivalent. The impact on timeframes is clear.
Influence of investment decisions
It might take five years to build and validate a stainless steel based multi-use (CIP/SIP) facility. However, it may only take two years for the equivalent single-use facility, so biopharmaceutical manufacturers can benefit from up to three years' worth of extra clinical data before pushing the button on what would be a multi-million dollar investment.
Enabling the operation of multi-product facilities
Single-use technology has clear advantages in a multi-product facility. For instance, operators will not need to validate CIP/SIP cycles or maintain costly utilities.
However, automation also allows operators to run multiple recipe-driven processes even when they have limited experience of the process being run.
For example, all TFF processes follow a certain high-level routine, but products will have differences in the recipe being executed. Being able to call up and run an automated process helps to eliminate any process errors.
Regulatory considerations
The more automated a process is, the more repeatable that unit operation should be. This helps biopharmaceutical manufacturers comply more easily with regulations, as it reduces process variation. Automation also enables training to be simplified and will reduce the potential for process deviations caused by manual operations and indeed, human error, which can impact on productivity and operator safety.
In addition, an automated system allows for the creation of a batch record along with the compliant storage of data and the audit trail for the data set, again helping biopharmaceutical manufacturers to meet regulatory requirements more easily - and allowing far less room for error.
Economic considerations
With biosimilars coming online, more focus is being placed on the cost of goods sold (COGS). Through automation, the number of people involved in a unit operation can be decreased and the supply chain around the process can be simplified. In effect, you can do more with less.
Continuous processing
Single-use systems are a key enabling technology for continuous processing. To allow continuous processing in single-use processes, the automation of valves, feedback from sensors and control logic will need to be in place. An automated approach, therefore, is essential for a single-use continuous process to work.
Conclusion
Single-use system implementation and single-use automation should be viewed jointly - and as shown above, automation can take the advantage gained from single-use to a much higher level.
Read the full white paper - Automation in Single-Use: Unlocking the True Potential of Single-Use Technology
This post was contributed by Guy Matthews, division marketing manager at Parker Bioscience Filtration, United Kingdom.
Parker Bioscience Filtration specializes in automating and controlling single-use bioprocesses. By integrating sensory and automation technology into a process, a manufacturer can control the fluid more effectively, ensuring the quality of the final product.
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Improve Accuracy and Efficiency by Tackling the Eight Wastes of Lean
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