Overview
A leading Fortune 500 biopharmaceutical company launched its first major bioreactor modernization in over 15 years—upgrading 140 bioreactors across R&D (5L), process development (100L), and production (2000L). Tasked with adopting modern Process Analytical Technology (PAT) for both perfusion and fed-batch processes, the client also needed to expand manufacturing capacity by 70%.
Catalyx delivered a comprehensive upgrade with minimal disruption, standardizing bioreactor control across all units. By implementing the OpenBIO® Open Architecture Bioreactor Controller platform, the company realized an estimated $300,000 ROI per installation per year, reclaimed 30% more lab and production space, and achieved a 70% increase in cell culture runs.
Key Challenges
Aggressive Timeline
The upgrade needed to be completed quickly, without interrupting ongoing operations.
Manual Operations
Operators had to manually configure each bioreactor, leading to inefficiencies and increased risk of error.
Limited Scalability
Custom, siloed setups made it difficult to scale or optimize processes across bioreactor systems.
Inconsistent Capabilities
R&D labs operated bioreactors from three different vendors, leading to inconsistent features and limited integration across platforms.
Our Solution
Catalyx designed a scalable, future-ready modernization strategy, replacing outdated control towers with OpenBIO while reusing key hardware components to minimize cost and disruption. The solution was rolled out in three strategic phases:
Step 1: System Assessment
We conducted a full evaluation of the existing bioreactor ecosystem. Engaging both scientists and operators, we identified pain points and opportunities for streamlining. These insights directly informed the design of OpenBIO®—a vendor-neutral, modular control platform that integrates seamlessly with any existing bioreactor system.
Step 2: Pilot Program
A pilot phase validated the new system by running the client's core cell culture processes (“golden recipes”). Successful outcomes confirmed readiness for full-scale deployment.
Step 3: Phased Implementation
Catalyx executed six phased installations over six months. Each was completed in less than a week during scheduled downtimes, ensuring uninterrupted operations. The result: a fully standardized, unified control system across 140 bioreactors.
Results & Impact
$300,000+ Annual ROI per Unit
The upgrade paid off quickly, delivering significant returns on each installation.
30% More Lab & Production Space
A compact and efficient design reclaimed valuable floor space while improving process flow.
70% Increase in Cell Culture Runs
Enhanced throughput across R&D, development, and production lines dramatically boosted capacity.
Unified Data & Platform Architecture
OpenBIO eliminated data transfer mismatches, integrating R&D, development, and manufacturing on a single platform for seamless scale-up.
Centralized Monitoring & Control
Operators can now manage and monitor all bioreactors remotely, removing the need for manual adjustments at each unit.
Improved Security & Compliance
A robust access control system enables user-specific permissions and groupings, ensuring regulatory alignment and operational integrity.
Conclusion:
Catalyx transformed the client's cell culture operations through a seamless bioreactor modernization strategy. With the implementation of the OpenBIO® platform, the company gained a unified, scalable, and efficient system—eliminating manual bottlenecks, standardizing processes, and dramatically increasing throughput. The results: 70% more cell culture runs, a 30% expansion in usable space, and an estimated $300,000 ROI per installation annually. This project not only optimized current performance but also positioned the company for long-term success in an evolving biopharma landscape.