Blog Image, Bioreactor Sampling

Precision Matters: The Role of Bioreactor Sampling in Industrial Biotechnology

In industrial microbiology and biotechnology, precise bioreactor sampling plays a critical role in ensuring product quality, optimizing processes, and maintaining compliance with regulatory standards. Sampling provides vital insights into microbial growth, nutrient consumption, and metabolite production, allowing producers to fine-tune operations for maximum efficiency and consistent results. Sampling bioreactors also needs to be done in a way that does not compromise the bioreactor’s efficacy and performance. 

Understanding Bioreactors and Their Role in Production

Bioreactors are specialized systems designed to support the controlled growth of microorganisms or cells under optimal conditions. They are used across industries, such as pharmaceuticals, food production, and biotechnology, for processes like enzyme fermentation, vaccine production, and biofuel development. A well-functioning bioreactor depends on several critical factors, including sterility, temperature, pH, oxygen supply, and nutrient availability.

Bioreactor sampling is an essential component of bioreactor operations. Proper sampling helps ensure that the bioreactor environment remains consistent and free from contamination, enabling researchers and producers to monitor and adjust parameters such as microbial activity, nutrient consumption, and metabolite levels.

The Importance of Aseptic Sampling Techniques in Bioreactor Operations

Aseptic bioreactor sampling is crucial for maintaining sterility within the bioreactor and ensuring the integrity of collected samples as growth is monitored. It helps prevent contamination from being introduced during sampling, which can compromise the entire production process, leading to product loss and financial setbacks (ScienceDirect, n.d.).

In addition to monitoring microbial growth, aseptic sampling techniques are essential for monitoring nutrients and metabolites. By assessing nutrient levels, producers can determine whether the microorganisms or cells have sufficient resources for optimal growth. Metabolite analysis helps identify the production of desired compounds or the accumulation of inhibitory byproducts. For instance:

  • Nutrient Monitoring in Bioreactors: Ensures glucose, nitrogen, and other critical substrates are maintained within the optimal range for microbial growth.
  • Metabolite Analysis in Bioprocesses: Tracks the production of target molecules, such as enzymes, or detects toxic byproducts that may impact efficiency.

Beyond sample collection, QualiTru’s aseptic ports can also be installed on fermentor top plates, allowing operators to aseptically introduce nutrients, pH adjusters, or other critical components without compromising sterility.

QualiTru’s aseptic sampling systems, such as the pre-sterilized TruStream Septa and TruStream7 Stainless Steel Ingold Ports, enable precise, contamination-free collection of samples for bioreactor process control, ensuring consistent quality and process optimization.

Challenges in Bioreactor Sampling and Modern Solutions

Traditional bioreactor sampling methods often present challenges, including:

  • Risk of Contamination: Manual sampling increases the risk of introducing contaminants into the system (ScienceDirect, n.d.).
  • Non-Representative Samples: Sampling from non-representative points may lead to incomplete or skewed data.
  • Time-Consuming Processes: Manual sampling can be labor-intensive, increasing operational inefficiencies.
  • Labor and Safety Risks: Systems relying upon steam sterilization consume significant energy and introduce health, safety, and environmental risks.

Unlike costly biopharma-specific sterile bag systems or the need to implement fully steamable ports, QualiTru’s aseptic sampling systems provide an effective, easy-to-use solution without requiring expensive installation. For operations without built-in steamable sampling ports, QualiTru’s solution is an optimal and scalable alternative, ensuring both sterility and ease of use.

QualiTru’s sampling systems address traditional sampling challenges by providing a closed system that eliminates the risk of contamination and enables representative sampling for bioreactors. By capturing samples from the top, middle, and bottom of the tank, producers gain a comprehensive microbial and nutrient profile, improving data accuracy and process efficiency. Additionally, customers report significant time savings and reduced safety risks by eliminating the need for steam sterilization before every sample.

Best Practices for Effective Bioreactor Sampling

To help ensure accurate and reliable bioreactor sampling, consider the following best practices:

  • Use Aseptic Sampling Techniques: Always employ sterile methods to prevent contamination during sample collection.
  • Implement Advanced Sampling Systems: Utilize modern sterile sampling systems designed to maintain sterility and provide representative samples.
  • Regularly Calibrate Equipment: Ensure all sensors and sampling devices are properly calibrated to maintain accuracy.
  • Train Personnel Thoroughly: Provide comprehensive training to staff on aseptic sampling procedures and the use of specialized equipment.
  • Monitor Key Metrics: Establish appropriate sampling intervals to track microbial growth, nutrient levels, and metabolite analysis in bioprocesses.
Bioreactor Port - Oxyrase
QualiTru sampling system in use atOxyrase, Inc.

By adhering to these practices and leveraging advanced sampling technologies, industries can enhance the reliability and efficiency of their bioprocesses, leading to improved product quality and compliance with regulatory standards.

We have been using QualiTru’s TruStream Stainless Steel Ports and Septa as an injection port for at least five years, and they work very well for this application. We’ve never experienced any issues with contamination from their products. The TruStream Septum allows us to add heat-labile ingredients to a sterile tank once the temperature drops to 60°C. As we plan to build our new fermentation reactor, we will definitely keep QualiTru in mind.

– Dan Legge, Production Manager at Oxyrase, Inc.

Why Choose QualiTru for Bioreactor Sampling?

  • No expensive installation required—simple setup for aseptic sampling
  • Cost-effective alternative to steamable sample ports and biopharma-grade sterile bags
  • Allows aseptic additions through fermentor top plates
  • Reliable sterility without the need for steam sterilization before every sample

Advancing Industrial Bioprocesses with Precision Sampling

Precision bioreactor sampling is a cornerstone of modern industrial biotechnology. By employing sterile sampling systems, producers can help ensure consistent product quality, reduce contamination risks, and optimize bioreactor performance. Ready to elevate your bioprocess operations? Explore QualiTru Sampling Systems for industry-leading aseptic solutions that support your production goals

Questions? Contact us at 651-501-2337 or complete our Contact Us form to learn more about our aseptic sampling solutions for bioreactors.

References:

ScienceDirect. (n.d.). Aseptic operation. Retrieved from https://www.sciencedirect.com/topics/engineering/aseptic-operation

Anne Bigalke is the Vice President of Business Development at QualiTru, where she plays a pivotal role in expanding the company’s vision across multiple food, dairy and biotech industry segments. Anne has a deep-rooted connection to the family business and vision to improve food safety and quality, spending her early years assembling sampling products and gaining hands-on experience across various operational roles while learning from industry thought leaders.

She holds a bachelor’s degree in International Political Economy from the University of Puget Sound in Tacoma, Washington, and an MBA from St. Catherine University in St. Paul, Minnesota. Before returning to QualiTru, Anne worked in Malaysia, where she managed six development centers, gaining valuable global business experience. Over the past 10 years, she has worked across all levels of QualiTru’s operations, including an overseas posting to establish business in Europe and other regions.

Today, Anne is focused on driving QualiTru’s strategic growth and expanding its presence across new markets and products. She is dedicated to building the company’s foundation for the next generation of leadership, ensuring its continued success in an evolving industry needs.