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Reusable bioreactors have been the benchmark standard for many decades, during which a large knowledge base on process control and scale-up has been developed. However, single-use bioreactors are increasingly being implemented in modern bioindustrial upstream processes. Many of these bioreactors deviate from the traditional stirred-tank design, but a number of companies have expressed a strong need for single-use bioreactors based on the strirred-tank design. A traditional stirred- tank design would enable users to optimize their scale-up processes based on both experience and well-established guidelines regarding scale-up elements as tip speed, mixing time, oxygen transfer, and specific power input. To meet that demand for improved scalability using single-use bioreactors, New Brunswick Scientific (NBS) has developed a new stirred single-use bioreactor called the CelliGen BLU system.

Whether you are culturing animal cells in an R&D laboratory or in a pilot production facility, your ability to precisely control all process parameters is critical. Culture yield depends on it, and should your process go into production, FDA requirements mandate it. Therefore the performance of your bioreactor’s controller is as important as a good vessel design, as an optimized medium formulation, or selection of the right cell line.
This article focuses on the process control capabilities offered by the CelliGen® BLU, New Brunswick Scientific’s new, benchtop stirred-tank bioreactor with single-use, 5- and 14-L vessels. While much has been written (1–3) about its unique vessels, non-invasive sensor design, and rapid turnaround time between runs, much less has been documented about its custom-configurable process control capabilities. Designed to provide the flexibility for high-density growth of animal or insect cell lines, the highly flexible CelliGen BLU bioreactor is as capable as it is easy to use.

During the past decade, single-use bioreactors have become widely accepted and often preferred in development and manu- facturing processes. In particular, single-use vessels have proven perfectly suitable for the cultivation of low-oxygen-demanding cell types such as mammalian and insect cells. These bioreactors can offer significant advantages over their reusable glass and stainless steel counterparts, including labor and cost savings, rapid turnaround between runs, and flexibility. This article focuses on single-use bioreactor design advancements introduced in the new benchtop CelliGen® BLU stirred-tank bioreactor from New Brunswick Scientific.

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An advanced new benchtop fermentor and cell culture bioreactor system has been developed, which for the first time enables you to optimize process control by integrating data from up to 11 external devices^*. This means that data from your scales, gas analyzers, supplementary pumps, cell mass sensors, and so on, can be directly added and cascaded with existing control loops. You can then calibrate those devices through the fermentor’s advanced touchscreen interface, as well as set alarms based on their data, and view the entire process in trend graphs. In the past, only large-scale fermentors or bioreactors with advanced control systems were capable of what can now be achieved on the benchscale.

New Brunswick Scientific has introduced a new device that automatically counts yeast cells in about 30 seconds, making manual counting obsolete. Like the original NuceloCounter^®, an automated device for counting mammalian cells, the new NucleoCounter YC-100 for yeast combines a fluorescence microscope with CCD camera and integrated image analysis software to perform rapid and accurate cell counts.