i-control Complete Process Control

Transcription

1 icontrol icontrol TOTAL TOTAL CONTROL CONTROL MAKE MAKE SELECTION SELECTION SELECT CONTROL OPTION FOR I-CONTROL i-control Complete Process Control

2 Applikon Biotechnology T H E B I O P R O C E S S I N G E X P E R T S O F F E R I N G T O T A L C A R E S O L U T I O N S F O R Y O U R L A B i-control i-control: the scalable bioreactor control solution i-control is an easy to operate bioreactor control system and utility console. This scalable control solution is used to control processes in bioreactor systems from laboratory scale to pilot plant and production scale. The seamless scale-ability saves time and money by offering a simpe scale-up of control strategy from research via pilot-plant to production. The i-control is available in a Single, a Dual bioreactor set-up as well as in a Quad (4 bioreactors) configuration. The system is supplied pre-configured and ready to use. Modularity The modular architecture allows the system to be used with a wide range of industry standard control platforms (like Siemens and Allen Bradley). i-control offers the solution for bioreactor control using industry standard hardware. The intelligent design of the software allows the system to be customized to virtually any bioreactor process without the need of re-programming the software. The i-control uses industry standard control platforms as Siemens and Allen Bradley and the system can be used with DeltaV as well. The control system comes in a lab version and a pilot/production version. The lab version controls up to 4 small scale autoclavable bioreactors (quad i-control) and up to 2 small Steam-In-Place bioreactor systems (dual i-control). The pilot/production version controls one bioreactor system and has the capability to control a Clean In Place (CIP) system for this bioreactor. Scale-ability The advantage of the i-control is that it brings the robust control that is usually only available in production to the laboratory. This enables easy recipe transfer between the lab, the pilot plant and production. Data from laboratory experiments is readily available for production since the control system easily integrates into the plant automation software. Expandability The smart design of the software allows the system to be easily expanded without the need for a PLC programmer on site. The i-control software contains numerous preprogrammed control loops that can be activated by the user once the appropriate hardware has been installed in the system. This offers easy expansion of the system and makes it very easy to add for, example, a pressure controlloop, a second ph or oxygen sensor or an additional balance based control loop for gravimetric feed. Human interface The i-control human interface is a color touch screen. The dedicated bioreactor control system has the most important functions available on the main page of the controller; Calibration, alarm signals, Starting/stopping of control loops, changing controller setpoints, viewing trend graphs and of course a synoptic overview of the process. Other screen views include sterilization view, Clean-In- Place view, alarm history view and many others. The i-control is developed to be used by biotechnologists and cell biologists. One of the key features is the simplicity of operation. Users are able to adapt control configurations due to changes in process demands without the need for a control expert on-site.

3 icontrol SYSTEM ARCHITECTURE SYSTEM ARCHITECTURE Local Human Interface inch LCD / TFT Gas Compartment max. 8 rotameter or MFC gasmixing / selection sparger / overlay internal I / O bus Electrical Compartment internal I / O bus optional third party PLC sensor connectors stirrer speed controller emergency stop Utilities Compartment max. 4 pumps water bath or cold water / heating blanket heating blanket water for condenser HARDWARE FEATURES PLC for process control Touch screen human interface for operation and visualization I/O system is an industry standard fieldbus system allowing easy maintenance and expansion Measured and controlled parameters include: ph (2 per bioreactor), DO2 (2 per bioreactor), Temperature (up to 10 sensors per bioreactor), Level, Foam, Pressure, Load cells for bioreactor weight, Balances for additions (up to 6 per bioreactor), Agitation, Biomass, Optical Density, MFC s (up to 8 per bioreactor), Internal variable speed and fixed speed pumps (up to 8 per bioreactor), External variable speed and fixed speed pumps(up to 8 per bioreactor), and many others. COMPLETE PROCESS CONTROL

4 COMPLETE PROCESS CONTROL Applikon Biotechnology Synoptic display Process status overview Software features The i-control offers advanced control features like: cascade DO2 with pressure, agitation and gas flow, total constant flow, up to 4 user definable control loops, balance addition control loops based on flow setpoint, balance addition control loops based on constant weight. Furthermore the i-control software offers fully automated and customizable SIP and CIP routines with an option of up to 10 temperature sensors in the bioreactor for continuous temperature mapping during SIP and CIP. i-control has local data storage for viewing trends of measured and controlled parameters. Industry standards The modular software design according to the ISA S88 standards eases validation, improves consistency across processes and plants making operation and system integration simple. SCADA Communication with supervisory software uses OPC via the integrated Ethernet port. OPC (OLE for Process Control) compliant communication eases integration into third party software. Benefits of OPC are: Time Reduction through lower system integration costs, ease of integration with plug-and-play connectivity. The i-control software is developed and documented according to GAMP guidelines. The comprehensive IQ (Installation Qualification), OQ (Operation Qualification) and GAMP development documentation guarantees easy cgmp validation. The validation documentation is available as an option. The i-control can be used in a 21CFR part11 compliant environment. Trending display for PID tuning

5 icontrol Cultivation process overview display Dissolved Oxygen controlloop display Highlights of the Allen Bradley platform The Allen Bradley version of the i-control uses the CompactLogix LC35 or LC43 PLC. The architecture of the Allen Bradley system allows the use of multiple human interfaces on a single PLC i-control system. An auto tuning PID control module is available as an option. The quad exists of 2 cabinets and the second cabinet can also be equipped with a touch screen for easy operation. Highlights Siemens platform The Siemens i-control system uses a Siemens S7-300 series PLC. Bioreactor sterilization display The sterilization recipe is completely customizable. The user can define the automatic pressure hold test acceptance parameters, sterilization temperatures and sterilization hold times for the different parts of the bioreactor. The same is true for the Clean-In-Place procedure. This is completely customizable by the enduser without the need for a PLC programmer. The optional i-control language module of the Siemens version allows the controller displayed language to be adapted to the local language.

6 T H E B I O P R O CA EUS ST I ON G C EL XA PV EAR TB S L OE F FS EYR SI NT G E TM OST A L C A R E S O L U T I O N S F O R Y O U R L A B i-control Re-instrumentation options for i-control The modular design of the i-control software and hardware makes it an ideal solution for retrofitting existing bioreactor systems. Updating the control system of an existing installation is a cost effective way for extending the life of your old bioreactor. The controller retrofit can be combined with a complete system check-up by the experienced and well trained Applikon service team. This retrofit and check-up can be done for Applikon or for other brand bioreactors. Spareparts and service The i-control uses industry standard components. For spare parts you have a choice of (local) suppliers. Of course Applikon is more than happy to supply you with first class after sales service and spare parts. You can also source components from your local supplier. This makes you independent of one specific supplier and guarantees maximum functionality of your i-control system by minimizing down time. Applikon has an extensive preventive and corrective maintenance program. Contact your local supplier for details. Applikon Biotechnology BV, Nieuwpoortweg 12, 3125 AP Schiedam, The Netherlands. P.O. Box 101, 3100 AC Schiedam, The Netherlands. T: +31(0) F: +31(0) E: sales@applikon-biotechnology.com Applikon AppliCare - V3X Subject to modifi cations - Printed by Applikon Biotechnology bv - The Netherlands September