Fully Automated Autosampling Control System

Industry

Biotech / Life Sciences / Industrial Automation

Scope

Closed-Loop Control / Autosampling Integration / MTP Standard / Process Analytics (PAT) / OT Architecture

Timeframe

12+ Months

  • 100%

    automated execution of the sampling sequence

  • 0

    Manual data entry required for sampling results

01

CLIENT

A Global Life Sciences innovator working on a next-generation bioprocessing platform. Their goal is to eliminate manual interventions in drug production by creating a self-driving system where critical quality attributes (CQA) are measured and controlled automatically in real-time.

02

BUSINESS NEEDS

The "Holy Grail" of modern bioprocessing is continuous, automated monitoring. The Client had a robust bioprocess controller and high-end analytical instruments, but they operated as separate silos. The missing link was the "Control Loop": manual bottlenecks, disconnected data, and integration barriers with third-party analytical devices.

03

CHALLENGE

To help our client achieve its goals, we overcome the following challenges:

  1. The Black Box Problem

    The "Black Box" Problem

    Integrating a closed third-party analytical unit that wasn't designed for external automated control.

  2. Orchestration Logic

    Orchestration Logic

    Creating a failsafe sequence: Trigger Sampling -> Transport Fluid -> Analyze -> Write Data Back with millisecond precision.

  3. Standardization (MTP)

    Standardization (MTP)

    Ensuring future analyzers could be plugged in without rewriting code by using Module Type Package standards.

  4. Data Correlation

    Data Correlation

    Merging high-frequency sensor data with low-frequency analytical data into one coherent dashboard.

04

SOLUTION

We engineered the Digital Handshake that bridged the gap between the bioreactor and the analytical lab. We built a fully automated Autosampling Control Loop. The solution entailed:

  • Interface Engineering (The Translator)
    • Reverse engineering of the device's API and development of a custom Middleware Driver to translate proprietary signals into industrial protocols.
  • The Logic Engine (The Brain)
    • Implementation of the Sampling Orchestration Logic and error-handling routines like "Sample Line Clogged" detection.
  • Unified Visualization (The Eyes)
    • Deployment of a Grafana-based PAT Dashboard, allowing operators to see analytical results plotted instantly alongside process parameters.
  • Operational Stabilization
    • Validated the loop through rigorous testing ("Runs Support") to ensure reliability over multi-week continuous processes.

We turned a disconnected lab bench into a cohesive organism. By closing the control loop between the bioreactor and the autosampler, we didn't just save time - we unlocked the potential for real-time feedback control. The system now 'knows' the state of the culture instantly, without a human ever touching a pipette.

Jacek Fischbach

Delivery Executive

Technology used

Industrial Automation MTP (Module Type Package) Middleware Development Process Analytical Technology (PAT) Grafana REST/gRPC APIs

05

OUTCOME

The project resulted in a robust, scalable system that achieved a fully functional automated cycle of sampling, analysis, and data ingestion. By eliminating manual data entry, the solution ensured total data integrity and process transparency, while the MTP-compliant architecture provided a vendor-agnostic foundation for future scalability.

  • Automated Feedback Loop
    • Achieved a fully functional automated cycle: Sample -> Analyze -> Data Ingest.
  • Data Integrity
    • Eliminated manual data entry errors. Results are automatically logged and timestamped in the central historian.
  • Vendor-Agnostic Design
    • The architecture is ready to accept different analytical devices in the future without major re-engineering.
  • Process Transparency
    • Provided 100% visibility into the sampling status and analytical results via unified dashboards.

06

IMPLEMENTED SOLUTION

  1. Mock-up Testing

    Mock-up Testing

    Developing "Virtual Analyzers" to stress-test the control logic safely before connecting physical hardware.

  2. Alarm Management

    Alarm Management

    Configured specific alarms for the autosampling subsystem (e.g., "Reagent Low") to alert operators via the dashboard.

  3. Zero Manual Entry

    Zero Manual Entry

    100% automated execution of the sampling sequence and real-time availability of CQA data.

  4. MTP Compliance

    MTP Compliance

    Implementation of Module Type Package standards for modular, interoperable lab automation.

  • 100%

    automated execution of the sampling sequence

  • 0

    Manual data entry required for sampling results

Is your lab equipment still operating in silos? Let’s integrate your analytical devices into a closed-loop control system.
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