TECNIC Bioprocess Solutions Partners with VEGA to Advance Measurement Technology in Bioprocesses
We are facing an exciting moment for biotechnology. In addition to the expansion phase it is currently experiencing, many chemical and pharmaceutical processes are transitioning into biotechnological processes. Amidst all these changes is TECNIC Bioprocess Solutions, headquartered in Girona, 80 kilometers from the city of Barcelona, which supports its clients in all phases of bioprocess implementation. Regarding pressure and level measurement technology, it relies on VEGA measurement instruments.
The company, founded ten years ago, is undergoing rapid growth. With a production area of 5000 m², TECNIC specializes in equipment for biotechnological and pharmaceutical applications for laboratories, pilot plants, and production facilities. Its tasks cover the entire manufacturing process, from 3D design and construction to equipment and instrumentation programming and commissioning. TECNIC has BSL2 laboratories for cell and microbial cultivation, which it uses to support clients. "We assist our clients in defining equipment for upstream or downstream processes, or during the scaling phase. We act as a link between R&D and production departments, offering scalable solutions to accelerate the industrialization process," explains TECNIC's operations manager.
In its early years, attention was focused exclusively on pharmaceutical applications, but in 2018, a new biotechnology department was added. Now, the company covers all common processes such as upstream (i.e., bioreactors or medium preparation tanks) and downstream (tangential flow filtration equipment). TECNIC offers a wide range of equipment ⇀ for laboratory (eLAB), pilot plant (ePILOT), or production (ePROD) applications. Bioreactors are devices that replicate optimal conditions for the growth of cell or microbial cultures by regulating temperature, pH, and partial oxygen pressure (pO2), as well as dissolved gas concentration and optionally optical density (TCD), cell density (VCD), or dissolved CO2. Dissolved oxygen control in the culture medium is achieved, for example, through cascade regulation that acts on variables such as agitation, aeration, or oxygen-enriched aeration. To ensure sterility in the biological reactor, sterile addition valves and a fully aseptic sampling system have been developed, which are connected to the SIP (Sterilization in Place) system.
Turbulent and viscous media conditions
Having reliable measurement values is a decisive factor for sophisticated processes. Regarding pressure and level measurement technology, the company relies on VEGA sensors since they started working on bioprocess plants several years ago. "In most applications, temperatures range from -10°C to +140°C during sterilization processes. We constantly deal with viscous media and turbulent conditions, but steam and CIP cleaning processes also affect the sensors," says, explaining the working conditions of the bioreactors manufactured at TECNIC.
Wide range of sensors
In their equipment, there is a wide variety of VEGA sensors installed, which, in turn, send their analog and digital signals to internally developed eSCADA software. The software, featuring industrial architecture for all equipment including laboratory setups, manages control parameters and recipe execution in compliance with CFR21 Part11 (FDA) regulations and GAMP5 guidelines. "We handle the calibration and commissioning of all sensors ourselves. Additionally, we can always rely on VEGA's technical support," comments.
The VEGABAR 28 is practically the standard sensor for pressure measurement. With its assistance, sterilization processes in bioreactors are regulated. The sensor is crucial for ensuring a pressure of 1.3 bars. The VEGABAR 28 is a universal pressure sensor with a ceramic measuring cell for measuring gases, vapors, and liquids up to 130 °C. The heart of the pressure sensor is the pressure measuring cell, which converts the applied pressure into an electrical signal. This signal, dependent on pressure, is converted into a standardized output signal by the integrated electronics. The sensor element is the proven CERTEC® ceramic measuring cell, which not only offers excellent long-term stability but also high overload resistance. The CERTEC® measuring cell is also a dry measuring cell without oil filling.
The VEGABAR 29 is, in turn, the standard sensor in tangential flow filtration (TFF) equipment, i.e., in the purification stages of biotechnological processes. The sensor monitors TMP (transmembrane pressure), a critical parameter for filtration. This process parameter is the average pressure of the feed flow on the permeate side of the membrane. TECNIC's tangential flow filtration (TFF) system for all equipment ranges is fully automated, allowing the TMP to be predefined, and the process can be controlled by acting on the check valve.
The company only occasionally uses the VEGACAL 62 capacitance rod measurement probe, but it is highly appreciated in CIP (Cleaning in Place) systems due to its high chemical resistance. It continuously measures the level at this point. On the other hand, the VEGAFLEX 81 (guided radar sensor) is more frequently used at various points in the processes, for example, to measure the level in tangential flow filtration tanks, where a higher measurement value precision is needed for reliable process control.
VEGAPOINT 11 and VEGAPOINT 23 level switches monitor the level at all points where ASME-BPE, EHEDG, or GMP standards must be met, for example, in the pump area. These sensors also perform well in sterilization processes. Thanks to their universal connections for hygienic adapters, the investment in installation is minimal. The sensors can also be used in the application without adjustment.
The compact radar sensor VEGAPULS 21, which also supports CIP processes up to 80 °C, is used for monitoring non-critical volume that does not require any contact with the product. If the level must be recorded with maximum precision and without contact with the product, the best choice is VEGAPULS 64, which monitors critical volumes in processes. This 80 GHz radar sensor for continuous level measurement in liquids is also suitable for SIP processes.
Finally, the VEGASWING 51 and VEGASWING 61 vibrating level switches are often installed, especially in applications where ASME-BPE, EHEDG, or GMP standards are not applied.
High appreciation of the service and assistance
"What we value most is the reliability of VEGA sensors. However, for us, service and, above all, VEGA's global technical support are very important, as we sell our bioprocess equipment internationally," says. Regarding installation, they have been impressed with the Bluetooth connectivity of the sensors. "Wireless connection to the operating instruments is really useful for commissioning and verification. Additionally, discrepancies can also be identified more quickly in daily practice," comments on his experience.
