understanding bioprocesses

From the lab... ...to the production

Real-time gas analysis and software for the management of bioprocesses

© Copyright 2017 BlueSens. All rights reserved.Information in this document is subject to change without notice.No part of this publication maybe reproduced, stored in a retrieval system, or transmitted in any form or any means electronic or mechanical, including photocopying and recording for any purpose other than the purchaser‘s personal use without the written permission of BlueSens.BlueSens gas sensor GmbHSnirgelskamp 2545699 Herten, GermanyPhone +49 2366 4995-500

BlueSens was founded 2001 in Germany and develops and manufactures analyzers and software for bioprocess applications. In 2015 the BlueSens Corporation was founded in Illinois.The motivation of BlueSens is to provide instruments and software so that their customers gain comprehensive understanding of their bioprocesses to get a maximum optimized process for maximum yield at maximum quality. To achieve that, BlueSens is offering a variety of gas ana-lyzers to monitor key parameters of bioprocesses.In general, BlueSens’ gas analyzers are installed directly in the process and measure in real-time gases such as CH4, O2/CO2, CO, H2 or Ethanol/Methanol. Each sensor is individually tested and adjusted in calibration. BlueSens

has developed a unique calibration process guaranteeing that every sensor is a hand-made unique and individually tested device. At the customer the sensors will provide measurement data and conditions in the fermenter can be consistently observed and documented resulting in a better analyza-tion and controlling of the process. The software BlueVis is becoming more and more important to be able to do that. It can collect data, it calculates, visualizes and logs additional information via soft sensors, and it controls actuators. With more than 15 years of experience, BlueSens will help you to gain a deeper understanding of your bioprocess and to run a controlled process.

Certified gas is led to each sensor for individual calibration

The founders and managing directors of BlueSens Dr. Udo Schmale (left) and Dr. Holger Müller (right)

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Understanding bioprocesses for more than 15 years

*The usability of the soft sensors requires the BlueVis software and depends on the set-up of the process and may require

additional equipment. Soft sensors by EXPUTEC® GmbH.

Gain essential information about your process in real-time*:

Biomass

Growth rate

µmax, Xs, Yxs

CER, OUR, RQ

Just one device for the parallel online measurement of:

�O2 and CO2

� Humidity

� Pressure

� No minimal gas flow needed

� Fluctuating pressure and humidity are auto- compensated

Dozens of mechanical connections for any application

Safe solution

�Non-invasive measurement: no sampling, no multi-plexing, no risk of contamination

�One analyzer per process means continuous real- time measurement without interruptions. Nothing will be overseen and you are in time with the process

�Get alarmed and never miss a sampling/testing time point again

� Easy to use with single-use fermenters behind a sterile filter

Safe time and money

� The BlueInOne is reasonably priced

�Understand your process in real-time to save time

�No personnel expenses for sampling or operating a mass spec

� Valuable instrument for the scale-up phase

Less stress

�High grade of automation

� Convenient control of your bioprocess

Flexible and easy to install

� Low risk of investment: Low initial cost, start with one and scale up

� No installation costs. You can easily install the BlueInOne

� If needed, you can use the BlueInOne for a new mea-surement set-up (e.g. for different steps of a scale-up process)

Convenient external display

Be on the winning team

� The leading fermenter-suppliers use BlueSens’ mea-suring solutions

� Use state of the art off-gas analysis

BlueBlue

Ready for

Know your process: Change your „black box“ into a well characterized process

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Combined CO2/O2 gas analyzer for microbial processes Add value to your process with BlueInOne

Discover BlueVis the new high performance software which helps you to manage your bioprocesses in the most efficient way.

�BlueVis for monitoring, acquisition and integration of data from all components and for process control

� Parallel real-time measurement

� Integrated calculation of OUR, CER, RQ, growth rate and biomass by EXPUTEC ®soft sensors

� Easy connection of various sensors and probes

� Keep track of the important process parameters

� Trigger actuators via automated controllers

� Integrated math sensors, connection to MATLAB

� Analog devices can be connected via analog/digital converter

� Integrated OPC server/client for data exchange to other systems and programs

PROCESSPARAMETERS

LOGGING &VISUALIZATION

PROCESSSOFTWARE

PROVIDESMEA

SUREMENT

OPTIM

IZES & CONTROLS CALCULATES & P

ROCE

SSES

SENSORS &PROBES

BIOPROCESS

BlueBlue

� Re-use equipment you already have

�Or use BlueVis to set-up your own bioprocessing system

� You don’t have equipment yet? Ask us for a complete pre-assembled system

Your advantages:

BlueInOne gas analyzer for monitoring exhaust gas: O2, CO2

Heating/ cooling

systems

Agitator control

Digital mass flow controllers for gas input control

pH, DO, cell density, bio- mass etc. and other probes for liquid phase measurements

Pumps for feeding

and pH control

Trace® C2 Control for: glucose,

lactate, meth-anol/ethanol in the liquid

phase

Integrated math sensors, connection to MATLAB via

integrated OPC server/client

Sensors and probes connectable to BlueVis, more possible

Brand Measurement of Phase Connection type to BlueVis

BlueSens O2, CO2, H2, CH4, humidity pressure, Methanol/Ethanol gas RS 485/USB

TRACE® Analytics glucose, lactate, methanol, and ethanol liquid Ethernet

Hamilton® probes pH, DO and more liquid RS485/USB, Bluetooth

Other digital sensors and probes various various RS485/USB

Soft sensors OUR,CER, RQ, growth rate, biomass various Internal calculations

Analog sensors various various Connection via analog/digital converter

digital

analog

Intelligent process software

with OPC-interface and mathematical

modelling capacity

Smart software: Open to other brand - Open to other systems

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The smart software for bioprocessesBlueBlue BlueVis: Take what you haveBlueBlue

The Yieldmaster is the most advanced automated Bio-Methane Potential (BMP) evaluation system on the market. It is a modular system consisting of microprocessor controlled infrared-gas sensors, precision volumenometers (MilliGascounter®*) and the related BlueVis software for data acquisition and process control. In general the CH4 sensors are the standard devices of the Yieldmaster. Sensors for other gases (CO, H2, EtOH for example) can be added optionally.

* Registered trademark. The MilliGascounter was developed at the University of Applied Science Hamburg under the leader-ship of Prof. Dr. Paul Scherer.

BlueBlue

Ready for

Set-up in a water bath

Set-up with heating jacket and standard preserving jars

BlueBlue

Ready for

BlueBlue

Ready for

preFermBCThe same sensors are also integrated in the BCpreFerm system, which is designed for process optimization (scale up) from flasks up to large-scale fermenters. The system comprises up to 12 sensors that are linked to a computer via an electronic multiplexer. The related software visualiz-es the results and calculates vital parameters such as the oxygen uptake-rate (OUR), the carbon dioxide emission rate (CER) and the respiration quotients (RQ) both on fermenters as well as on flasks.

� Visualization of the process

� Increase of reliability and repeatability

�Dedicated process optimization without limitations (e.g. oxygen, nutrients etc.)

� Predictions for your scale up

The BCP- sensor series for the easy in-situ analysis.

� Each sensor is for a single gas: H2, CO2, CO, Ethanol/Methanol, O2, CH4

� PA or Aluminium housing (IP65)

� Easy installation in gas pipes or on shake flasks and fermenters

� Reasonably priced process analysis

MasterYield

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Automated Bio-Methane Potential evaluation More analyzing systems and sensors

Sensor CO2 CH4 CO EtOH BlueInOne FermMeasuring range 0 … 10 Vol. % 0 … 100 Vol. % 0 … 30 Vol. % 0.3 … 25 Vol. %6 0 … 10 Vol. % CO2,

0.1 … 25 Vol. % O2

0 … 25 Vol. % 0 … 100 Vol. % 0 … 25 Vol. % CO2,0.1 … 25 Vol. % O2

0 … 50 Vol. %1 0 … 10 Vol. % CO2,1 … 50 Vol. % O2

0 … 25 Vol. % CO2,1 … 50 Vol. % O2

Measuring principle Infrared, dual wavelengths Infrared, dual wavelengths (CO2) / ZrO2 (O2)

Accuracy < ± 0.2 % FS* ± 3% reading

Long-term stability2 < ± 2% reading / year

Lifetime sensor element > 3 years Approx. 3 years (CO2), 15,000 operating hours (O2)

Housing Aluminum, IP 65Dimension (WxDxH) mm Dimension (WxDxH) inch Weight

100 x 131 x 118 3.94 x 5.16 x 4.64 900 g (1.98 lb)

100 x 131 x 118 3.94 x 5.16 x 4.64900 g (1.98 lb)

100 x 131 x 1183.94 x 5.16 x 4.64900 g (1.98 lb)

100 x 131 x 1183.94 x 5.16 x 4.643000 g (6.61 lb)

170 x 150 x 1205

6.69 x 5.91 x 4.725

4000 g (8.82 lb)

Housing PA6Dimension (DxH) mm Dimension (DxH) inch Weight

80 x 130 3.15 x 5.12350 g (0.77 lb)

80 x 1303.15 x 5.12350 g (0.77 lb)

80 x 1303.15 x 5.12350 g (0.77 lb)

80 x 1303.15 x 5.12350 g (0.77 lb)

Not available

Material in contact with gas

Steel 1.4404 / Sapphire / Viton / PTFE Stainless steel / Viton / Sapphire / PTFE / Polymer H.L. / Nitrile

Connection6 G 1¼”, GL 45, Tri-Clamp, hose connection 4-12mm etc. ¼“ – 1 ¼“6, hose connection 4-12mm etc.

GeneralOperating temperature Max. -25 – 55 °C / -13 – 131 °F6 15 - 40 °C / 59 - 104 °F

Storage temperature 0 – 60 °C / 32 – 140 °F

Pressure range (absolute): 0.8 – 1.3 bar / 11.6 – 18.85 psi6 absolute pressure

Storage humidity 75% RH noncondensing > 75% RH noncondensing

Operating humidity 0 ... 100% RH3 0…100% RH

Integrated humidity compensation

Power supply (max.) 12 or 24 VDC, 1-2 A 24 VDC, 1 A

Output RS232, 4-20mA, USB, Ethernet4 RS232, RS485 Modbus, 2x 4-20mA, USB, Modbus OPC server (with BlueVis)

Maintenance once a month 1-point calibration with ambient air or nitrogen (other conditions on request)

One point calibration with ambient air once a month (other conditions on request)

Maintenance yearly Optional factory calibration with certified gases

CE EN61326-1:1997 +A2:1998 EN61326-1:2006 / FCC 15:2009 Subpart 107/109, ICES - 001:2006

Sensor BlueInOne Cell O2 O2ec H2

Measuring range 0 … 10 Vol. % CO2,0 … 100 Vol. % O2

0.1 … 25 Vol. % 0 … 100 Vol. % 0 … 100 Vol. %7

0 … 25 Vol. % CO2,0 … 100 Vol. % O2

1 … 50 Vol. %

Measuring principle Infrared, dual wavelengths (CO2) / Galvanic cell (O2)

ZrO2 Galvanic cell Thermal conductivity

Accuracy < ± 0.2 % FS* ± 3% reading

Long-term stability2 < ± 2% reading / year

Lifetime sensor element Approx. 3 years (CO2), approx. 900 000 Vol. % h operating hours at 1 bar (14.5 psi) (O2)

15,000 operating hours Approx. 900.000 Vol.% h operating hours at 1 bar (14.5 psi)

> 3 years

Housing Aluminum, IP 65Dimension (WxDxH) mm Dimension (WxDxH) inch Weight

170 x 150 x 1205

6.69 x 5.91 x 4.725

4000 g (8.82 lb)

100 x 131 x 1183.94 x 5.16 x 4.64900 g (1.98 lb)

100 x 131 x 1183.94 x 5.16 x 4.64900 g (1.98 lb)

100 x 131 x 1183.94 x 5.16 x 4.64900 g (1.98 lb)

Housing PA6Dimension (DxH) mm Dimension (DxH) inch Weight

Not available 80 x 1303.15 x 5.12350 g (0.77 lb)

80 x 1303.15 x 5.12350 g (0.77 lb)

80 x 1303.15 x 5.12350 g (0.77 lb)

Material in contact with gas

Stainless steel / Viton / Sapphire / PTFE / Polymer H.L. / Nitrile

Steel 1.4404 / Viton / PTFE Steel 1.4404 / Viton

Connection6 ¼“ – 1 ¼“6, hose connection 4-12mm etc.

G 1¼”, GL 45, Tri-Clamp, hose connection 4-12mm etc.

GeneralOperating temperature 15 - 40 °C / 59 - 104 °F Max. -25 – 55 °C / -13 – 131 °F6

Storage temperature 0 – 60 °C / 32 – 140 °F

Pressure range (absolute): 0.8 – 1.3 bar / 11.6 – 18.85 psi6 absolute pressure

Storage humidity 5...100% RH noncondensing > 75% RH noncondensing 5...100% RH noncondensing 75% RH noncondensing

Operating humidity 5...100% RH noncondensing 0 ... 100% RH3 5...100% RH noncondensing 0 ... 100% RH3

Integrated humidity compensation

Power supply (max.) 24 VDC, 1 A 12 or 24 VDC, 1-2 A 24 VDC, 1-2 A

Output RS232, RS485 Modbus, 2x 4-20mA, USB, Modbus OPC server (with BlueVis)

RS232, 4-20mA, USB, Ethernet4

Maintenance once a month One point calibration with ambient air once a month (other conditions on request)

1-point calibration with ambient air or nitrogen (other conditions on request)

Maintenance yearly Optional factory calibration with certified gases

CE EN61326-1:2006 / FCC 15:2009 Subpart 107/109, ICES - 001:2006

EN61326-1:1997 +A2:1998

* = full scale1 = accuracy < ± .0.5 % FS* ± 5% reading2 = with monthly 1-point calibration3 = not compensated4 = Ethernet with BACCom5 = stainless steel housing, dimensions depends on flow adapter6 = others on request7 = binary mixture

* = full scale1 = accuracy < ± .0.5 % FS* ± 5% reading2 = with monthly 1-point calibration3 = not compensated4 = Ethernet with BACCom5 = stainless steel housing, dimensions depends on flow adapter6 = others on request7 = binary mixture

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Everything at a glance: product overview Everything at a glance: product overview

BlueSens gas sensor GmbHSnirgelskamp 25 45699 Herten GermanyPhone: +49 2366 4995-500Fax: +49 2366 4995-599E-mail: info@BlueSens.de

BlueSens Corporation855 N Wood Dale Rd. Suite A Wood Dale, IL 60191 USAPhone: +1 847 201 3124E-mail: info@BlueSens.com BlueSens.comBlueSens.de

BlueBlue Visit us at BlueSens.com