The BIO07027 Bioprocess Engineering Theory module looks at how living systems and engineering fit together. It starts with how cells behave and ends with how those same cells can be guided to make things we need – medicines, enzymes, fuels. By the finish, learners can see how each stage, from culture to clean-up, ties into the wider design of a working bioprocess.
What makes the module stand out is the balance of theory and the real plant floor. It turns big ideas into steps that match Irish industry practice – careful design, constant monitoring, and quick responses when readings drift.
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The design of process control systems in bioprocessing is a critical business need, as it helps to improve product quality and safety, increase efficiency in operations and reduce press turnaround time. Process control systems also allow decision makers to more accurately understand the current state of their biological process, providing detailed analysis of every step and providing greater awareness of any potential bottlenecks.
Well-designed process control systems facilitate smarter business insight such as enabling companies to minimize costs and provide regular performance data for forecasting. Ultimately, robust process control systems help ensure minimal risk, fewer errors, and reduced contamination risks in batch production–allowing for faster delivery times, higher yields, and better pricing for the consumer.
A control system works like a quiet conversation between machines. At its core sit the process controllers, the “brains” that interpret signals and decide what to do next. These send instructions to actuators — valves, pumps, or drives — which physically adjust the process. Feedback sensors return information on temperature, flow, or concentration, confirming whether changes worked.
Alongside these sit input devices such as switches and manual overrides, all linked by secure communication lines. In a bioprocess lab in Cork, for instance, small PLC panels might connect fermenter probes to a central monitor through Ethernet loops. For safety, interlocks stop incompatible actions. When tuned well, the whole system behaves like a steady hand — responsive, safe, and adaptable as batches evolve.
The operation of a modern Programmable Logic Controller (PLC) system is based on the transfer and operation of digital signals and tooling. Inputs to the system come from such items as sensors, pushbuttons, switches, or other sources and are connected to the PLC using specialized cables designed for this type of application. These inputs are then read by the PLC and used in coordination with an associated program in order to control any associated outputs.
Outputs from a PLC system could represent motor controls, valve positions, alarms, etc., that can be connected directly to the device being controlled by the PLC. In order to operate, the PLC requires a special program that can be entered through various methods including Ladder logic diagrams written in special software packages or even programs written in a computer language like C++.
Once programmed with appropriate instructions, data transfers between inputs and outputs can be processed according to rules established in the program, allowing for the automatic operation of machines and processes that would otherwise need manual control.
Biopharmaceutical production depends on continuous measurement. The key systems in use include chromatography detectors, pH and conductivity meters, and dissolved-oxygen sensors. Each one provides live data so that culture conditions stay stable from start to finish.
Modern setups often combine these with online spectrometry and temperature mapping. The readings flow into a central control panel or SCADA screen, letting engineers see the full process in real time. Automated calibration routines cut down manual work and reduce mistakes that once came from tired eyes on night shifts.
These systems, when used together, turn a risky biological process into a repeatable industrial craft. The outcome is predictable batches, reduced waste, and stronger confidence in the final drug or enzyme product. All the same, the best technology still relies on good human oversight — someone to notice the odd reading that doesn’t feel right.
Supervisory Control and Data Acquisition (SCADA) systems are one of the most important aspects of modern bioprocessing. These have become integral tools for a wide range data acquisition, analytics, monitoring and control. SCADA systems use input/output devices, network communication capability and intelligent controllers to collect data from different points in the bioprocessing environment.
This enables remote monitoring and control over processes in a secure and reliable manner. Process variables like temperature, pressure, flow rate and so on can be tracked using the collected data. Based on this information, process parameters can be adjusted as necessary to optimize results while maintaining quality standards across all bioprocessing operations.
As such, SCADA systems are indispensable components of any modern bioprocessing facility.
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