Single-use bioreactors, also known as disposable bioreactors or single-use reactors are commonly used in biopharmaceutical manufacturing for cell culture, fermentation, and production of biologics such as vaccines, monoclonal antibodies, and recombinant proteins.

It is one of the most relevant pharmaceutical instruments for laboratory and manufacturing processes.

Unlike traditional stainless steel bioreactors designed for multiple uses and require cleaning and sterilization between batches, single-use bioreactors are intended for one-time use and are disposed of after a single batch. They have become an integral part of modern bioprocessing workflows due to their efficiency, flexibility, and cost-effectiveness.

Accurate measurement of the liquid flowing into and out of the bioreactor and ATF filter is important during the process, which will affect the quality, lead time, and cost efficiency of biopharmaceutical products.

Naturally, non-invasive flow measurement sensor for accurate measurement becomes a crucial component in single-use bioreactors.

1. Prevents Contamination

In single-use bioreactors, maintaining a sterile environment is critical to avoid contamination of the biological cultures or substances being processed. Non-invasive flow measurement techniques, such as ultrasonic flow meters or ultrasonic flow sensors, allow for real-time monitoring of flow rates without the need for physical contact with the biofluid, reducing the risk of introducing contaminants into the bioreactor.

2. Preserves Sterility

By utilizing non-invasive flow measurement sensors, operators can monitor and control the flow of media, nutrients, or gases in the bioreactor without compromising the sterile environment inside the disposable bag or vessel. This helps preserve the sterility of the single-use bioreactor system throughout the entire production process.

3. Enhances Process Control

Accurate and real-time flow measurement is essential for maintaining optimal process conditions in single-use bioreactors. Non-invasive flow measurement systems provide precise data on flow rates, allowing operators to adjust parameters such as nutrient feed rates, and speeds to optimize cell growth, metabolism, and product yield.

4. Facilitates Scale-up and Scale-down

Non-invasive flow measurement sensors enable easy scalability of bioprocesses in single-use bioreactors. By accurately measuring flow rates without disrupting the process, operators can scale up or scale down production volumes based on the desired batch size or production requirements.

5. Reduces Maintenance Requirements

Non-invasive flow measurement sensors do not require direct contact with the measured fluid. This minimizes the need for maintenance and cleaning of sensors, reducing downtime and improving operational efficiency in single-use bioreactor applications.

XY-TEK's CG Series Ultrasonic Flow Sensor, with its unique non-invasive measurement method, can achieve precise measurement of process flow in various types of bioreactors.

Addressing contamination risks and high maintenance costs, further improving the efficiency and quality of biopharmaceutical processes.

Here are some key benefits CG Series Clamp-On Ultrasonic Flow Sensor can add to the Single-Use Bioreactors.

1. Wide Measurable Flow Ranges

The CG Series ultrasonic flow sensors accommodate a wide range of flow rates, ranging from 0-1000 mL/min.

2. Industry-Leading Flow Rate Accuracy

Featuring ±1% accuracy, the CG series ensures precise measurement for critical processes such as protein production and cell culture.

3. Clamp-on Design, Hassle-free Installation

Available in 12 different tubing size options, suitable for outer diameters (OD) ranging from 4mm to 30mm, ensuring easy installation on various sizes of Bioreactors.

4. Non-Invasive Measurement, Reduced Risk of Product Contamination

This is particularly important in the biopharmaceutical industry, where maintaining product purity is essential to ensure the safety and efficacy of the final product.

5. Compatible with multiple Single-Use Bioreactors to optimize processes

a). Accurately monitor flow variations during the protein purification process to ensure consistent liquid flow rates at each step.

b). Real-time flow data monitoring to promptly adjust operational parameters in response to changing flow requirements.

c). Once abnormal flow rates are detected, quick identification of faulty components can be made for convenient troubleshooting.

Please feel free to contact us at global@xy-tek to discuss how the XY-TEK CG series ultrasonic flow sensor can benefit your product and contribute to your success.

Our sensor experts would be delighted to arrange a product demonstration or provide further information to assist you in making an informed decision.