Hybrid bioreactor system combines single-use flexibility with stainless steel reliability.

Custom automation and ergonomic design enable seamless integration of single-use equipment into GMP-compliant biopharma infrastructure.

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Hybrid systems, tailored for performance. Benchmark in flexible biopharma design.

ZETA is a global pioneer in the engineering of “hybrid” systems, that combine stainless-steel and single-use technology. The approach results in top flexibility and stability in performance, as was demonstrated some years ago by a landmark project with a customer in Switzerland. The fully customized solution involved the integration of four single-use bioreactors and, in a subsequent project, a second production line as a mirrored version of the primary system.

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The challenge

A fully functioning, GMP-compliant system is needed, and customer-specific standards and requirements are to be applied. Apart from routing of tubes, hoses and cables being a complex issue, the integration of single-use units into the overall automation system is challenging. Not each of the standard software packages provided by suppliers of single-use equipment can be natively fully integrated into the automation environment. This might easily lead to automation islands, which would cause considerable additional work over the entire lifecycle of the systems.

The solution

Automation: vertical system integration

The ZETA automation approach to single-use technology enabled complete integration of the single-use bioreactors (50 L, 500 L, 2x 2000 L) and further equipment (scales, TCUs) without the creation of automation islands. Customer-specific standards were implemented through intelligent automation strategies, thereby generating added value for process control. The hardware and software for automation were delivered as “ready-to-use.”

“Hybrid” plant design for top flexibility, safety and stability in performance

The project included the design, manufacture and installation of a stainless-steel work platform with utility pipework for the cleanrooms. ZETA developed a space-saving design for the pipework and tubing. The routing of the pipework greatly improved the EHS aspect. The plant was designed for easy cleaning and maintenance, with ergonomic access to the single-use equipment.

Services

Stainless steel platform for integration of four single-use bioreactors (50 L, 500 L, 2x 2000 L).

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Maximilian van de Graaf

Head of Sales Automation

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