Overview
A leading life sciences company faced operational and support challenges with its aging bioreactor control units. Originally supplied by Pall and later acquired by Cytiva, the 10L, 50L, and 100L single-use bioreactor systems relied on Siemens-based control towers with single-use bag holders and mixers. With Cytiva discontinuing support, the client urgently needed a modernization solution to ensure seamless operations while minimizing downtime and disruption.
Challenges
Operational Vulnerability & Loss of OEM Support
With Cytiva discontinuing support and no in-house Siemens PLC expertise, the client faced a heightened risk of downtime, worsened by reliance on external integrators unfamiliar with the system.Cost Concerns High Replacement Costs: The client initially anticipated a costly full system replacement—including vessels and controls—raising concerns over significant capital expenditure.
Aging Infrastructure & Reliability Risks:
The aging control towers depended on outdated components like peristaltic pumps, mass flow controllers, and analyzers, increasing the risk of failures and production disruptions.
The company needed a streamlined validation process to minimize internal resource strain, while ensuring full GMP compliance, a critical requirement for regulatory approval.
Our Solution
Catalyx OpenBIO ® Open Architecture Bioreactor Controller: A Comprehensive Modernization Solution
Catalyx North America delivered a seamless modernization strategy by replacing outdated control towers with OpenBIO controllers, while preserving key bioreactor components to maximize efficiency and cost-effectiveness. This streamlined approach involved the following key steps:
Step 1: Optimized Hardware Utilization
Retained existing bag holders, load cells, and mixers to reduce costs while preserving system integrity. Integrated the original motor with Catalyx’s VFD for improved control, and connected load cells to the OpenBIO Scale Controller for precise, real-time weight data.
Step 2: Advanced Control System Upgrade
Replaced legacy components with high-performance, OpenBIO-compatible alternatives for greater reliability and efficiency. Introduced a scalable OpenBIO controller, eliminating Siemens PLC dependency and enabling streamlined, future-ready operations.
Step 3: Rapid & Seamless Implementation
Executed system replacement and qualification in under three days, maintaining operational continuity. Provided standardized documentation to simplify GMP validation and ease internal workload.
Step 4: Training & Future-Ready Scalability
Delivered in-depth training and support, enabling in-house system management. Designed a scalable solution to support future growth without relying on external integrators.
Outcomes
$900K+ in Cost Savings
Avoided costly full system replacement by modernizing controls and maximizing the longevity and performance of existing bioreactor systems.
Rapid 3-Day Installation
Completed seamless implementation and qualification in just three days, minimizing operational disruption and enabling a faster return to production.
Effortless GMP Compliance
Catalyx’s comprehensive documentation package streamlined validation processes, reducing the burden on the client’s internal team and ensuring full compliance.
Enhanced Operational Autonomy
Provided comprehensive training, equipping the client’s team with the expertise to independently maintain and troubleshoot their systems, reducing reliance on external support.
Client Testimonial
"Our initial outlook was grim. We thought we were stuck with unsupported equipment or faced with an expensive overhaul. Catalyx provided a solution that not only modernized our systems but also empowered our team to maintain them without outside reliance. OpenBIO was a game-changer for us."
Conclusion
Catalyx showcased the unmatched flexibility and scalability of OpenBIOby seamlessly upgrading a legacy bioreactor control system. Through strategic reuse of key components and a swift, cost-effective implementation, Catalyx minimized costs, downtime, and validation complexities—enabling the client to accelerate innovation and drive sustainable growth.