BIO-S-C series stainless steel cell culture system

The Willon BIO-S-C stainless steel bioreactor is positioned in the high-end segment of the industry. Product design is primarily driven by modularity, automation, and intelligence, aiming for innovation, energy efficiency, and simplicity. It provides a range of stainless steel bioreactors, preparation systems, concentration and purification systems, material transfer systems, water distribution systems, and related complete equipment products for the biomanufacturing industry chain, from laboratory (research, teaching) R&D to pilot scale-up and large-scale industrial production of animal cells, plant cells, insect cells, and microbial cultures. Willon can provide stainless steel cell culture bioreactors up to 20,000L and microbial fermentation systems exceeding 100 tons. Customization is available based on cell lines and product types, ensuring reliable equipment quality. Advanced auxiliary design methods such as CFD simulation are introduced to ensure that the structure of the reactor and accessories meets the cultivation needs. Based on its engineering capabilities, it can provide professional water, electricity, and gas layouts as well as information system solutions to ensure the rationality and safety of the entire production process. In terms of cultivation processes, it can meet various process requirements such as batch, fed-batch, and perfusion cultures, supporting high-density, aerobic, and anaerobic fermentation, and is widely used in pilot and large-scale production by biomanufacturing companies such as vaccines, monoclonal antibodies, gene engineering drugs, and synthetic biology.

Product Features

● Modular design, optimized piping process, reasonable structure, and compact installation reduce floor space while facilitating operation and maintenance, ensuring production continuity and stability.

● Complete factory pre-installation and pre-commissioning ensure equipment quality and shorten on-site installation time, benefiting the client's work arrangements and accelerating project progress.

● The equipment strictly follows GMP regulations and is designed according to ASME BPE standards. Material interfaces all use hygienic NA interfaces. Pipe design and installation have strict dead-angle control, aiming for L<2D to avoid dead angles and blind pipes. Pipes are installed at a reasonable inclined angle, and drainage tests are conducted before leaving the factory to ensure no residue and prevent contamination risks.

● ASME-BPE standard piping and fittings are selected, and automatic welding is used. Each weld is inspected with a borescope, ensuring fluid flow and the highest level of piping system cleanliness under sterile conditions. This minimizes leakage and contamination risks from the source.

● The design fully considers various process requirements and has key parameter process control functions, such as temperature control, pressure control, material mixing, level control, DO control, pH control, stirring speed control, and gas flow control. It can monitor and adjust key process parameters in real-time to ensure stable and controllable cultivation processes.

● High-quality electrodes are selected, ensuring high control accuracy, good stability, and high process production consistency.

● The system is equipped with multiple cold-point temperature probes and a drain valve at the end. The sterilization temperature control design is reasonable, ensuring thorough sterilization while saving pure steam usage, making sterilization reliable and energy-efficient.

● Cascade control, such as four-level cascade control of dissolved oxygen (linking dissolved oxygen with air, oxygen, nitrogen, and stirring speed, and enabling automatic sequencing).

● Independent configuration of surface aeration/deep aeration, microbubble/small bubble aeration, automatic proportional adjustment of AIR, CO2, O2, and N2. Mass flow sensors for inlet gas are combined with exhaust control valves for dynamic flow continuous aeration.

● Fully automatic CIP/SIP ensures perfect cleaning results and consistent cleaning and sterilization parameters for each cycle, facilitating validation. This includes fully automatic empty tank, full tank, and single-pipeline cleaning and sterilization, automatic pressure holding during sterilization, and automatic cooling after sterilization completion. One-button automated operation.

● Adaptive PID control automatically adjusts PID setpoints for optimal control of pH, dissolved oxygen, temperature, and other parameters. This shortens process optimization time, especially for first-time operation or new projects.

● Independent sterilization sampling device, sampling position not higher than 1/4 of the culture volume, with cold point detection. The sterilization pipeline is specially designed to allow for multiple samplings after a single sterilization.

● Redundant design of exhaust filters allows for online filter replacement and sterilization. A tail gas microbial inactivation device is installed to sterilize the exhaust gas, ensuring biosafety. Sterilization temperature is settable, and exhaust gas temperature has real-time and historical curves.

● An automatically online sterilizable four-valve feed system, each set consisting of 3 pneumatic diaphragm valves and 1 manual diaphragm valve, allows for automatic SIP/CIP operation and is used for adding media, inoculation, defoaming, and acid/base addition.

● Automatic online sampling, online monitoring of nutrients, metabolites, and cell growth (optional).

● Optional cell density sensor for online monitoring of cell density. A dedicated cell density module allows for online measurement of cell density and feedback feeding. Expandable to include tail gas analysis and online glucose detection modules.

● Supports wireless remote control (mobile phone or tablet).

● Comprehensive validation system: DQ, IQ, OQ, PQ, FAT, and SAT, assisting clients in passing FDA and GMP validation.

● Ai-BIO bioprocess big data analysis software provides advanced process control and data analysis.