Premier Control Technologies Fluid Solutions
The controlled flow of Supercritical CO2 has been used as a green, efficient and non-biocidal solvent within the creation of scaffolds used within biochemical research. The pore spaces within the scaffold are used to support the cells or tissue being cultivated with the sizing and spacing of these pores being crucial. Equally important is the fact that the former presence of scCO2 does not interfere with cell growth – a draw-back of traditional solvents. Such cell/tissue cultures also benefit from a controlled or modified atmosphere especially when precise humidification is required.
Biochemistry labs and pilot facilities across the UK and Ireland demand precise, cleanable, and easily auditable control of gases, liquids, and utilities—from incubator atmospheres and bioreactor sparging to UF/DF back pressure and WFI/PUW verification. The technologies below focus on hygienic design (ASME BPE/USP Class VI where applicable), rapid integration with PLC/BMS systems, and non intrusive options that reduce downtime.
Below are some examples of typical applications where we succeed:
Stable, responsive control of O₂, CO₂, N₂ and air is central to reproducible cell growth and media conditioning. Bioreactors typically require wide turndown to support seed, growth and production phases without hardware swaps. Materials compatibility (316L/USP Class VI) and resistance to in line moisture support hygienic use and washdowns. Digital protocols simplify integration with Pharma 4.0 initiatives and PAT. Fast step response reduces DO/CO₂ overshoot and shortens stabilisation time after set point changes. Multi gas capability helps R&D groups standardise instrumentation while retaining flexibility across projects.
Supercritical CO₂ (scCO₂) offers a green, non biocidal solvent route to create porous scaffolds with precise pore structures, supporting tissue and cell based research. Maintaining consistent pressure and temperature as CO₂ passes through critical points is essential for reproducible scaffold morphology. Back pressure control at the unit outlet stabilises density and solvation behaviour. The valve must tolerate high pressures/temperatures and mixed phases. Rapid set point changes should settle without hysteresis to protect sample integrity. Robust, cleanable construction helps labs move from feasibility to pilot scale.
Buffer/media make up must achieve accurate ratios, low shear, and validated hygiene. Dose steps and ramps should be repeatable, and wetted materials must suit caustics, acids, and sanitants. Self draining, electropolished valves minimise hold up, while programmable pumps enable repeatable recipe cycles with back suction to prevent drip. Integration to PLCs with analog/RS 485 control simplifies interlocks (e.g., level/weight permissives). Fast tubing changeover and multi channel options help R&D and pilot teams adapt quickly without complex CIP tooling.
Final fill and micro dosing steps require sub percent accuracy, low pulsation, and clean, compact hardware for isolators/RABS or benchtop automation. Valveless architectures minimise wear parts and drift, improving repeatability across long campaigns. Chemical inert wetted paths enable compatibility with buffers, enzymes and solvents. Fast response helps synchronise with vision or check weigh controls. Low maintenance reduces downtime and simplifies validation.
Chromatography columns often benefit from stable outlet back pressure to improve peak shape and reproducibility, especially at low flows or with viscous buffers. Conventional spring BPRs can suffer from stiction and hysteresis, causing unstable pressure and retention time shifts. A frictionless, pilot operated BPR maintains set point with high resolution over wide turndown, even for mixed phases. Minimal dead volume and small port sizes suit lab scale skids.
UF/DF steps require tight trans membrane pressure (TMP) control to protect product quality and optimise flux. Single use systems increasingly demand sterile, disposable components with clean, scalable control. Fast changes in permeate/retentate flows should not disturb set points. The BPR should present minimal hold up and be easy to automate with an electronic pilot.
SIP/CIP reliability depends on stable clean steam pressure to maintain temperature profiles and sterilisation lethality. Sanitary construction, self draining geometries and CIP/SIP compatibility are mandatory. Regulators must withstand frequent cycles and provide repeatable set point control. Documentation (materials, surface finish) supports QA audits. Remote set point options allow automated recipe control.
WFI/PUW loops require continuous verification without breaching sterile boundary or causing pressure losses. Clamp on ultrasonic meters allow retrofit on live systems, support energy calculations for heat sanitisation loops, and integrate to BMS with standard protocols. No moving parts reduce maintenance and risk of contamination. Suitable transducer sets cover small risers to large mains.
Analytical methods (GC, ELSD, MS interfaces, glovebox sensors) require stable, low leakage UHP gas delivery. Two stage cylinder regulators minimise outlet drift as bottles deplete. Electropolished 316L, UHP seats/diaphragms and VCR® ends reduce adsorption and permeation. Availability of low range outlet options helps protect instruments. Clean room assembly and oxygen cleaning support GMP labs.
Small reactors and bench pressure vessels need smooth, accurate vacuum and slight positive control for degassing, headspace control, and sampling under controlled pressure. Traditional valves can exhibit stiction, making fine control difficult and causing oscillation. A precision vacuum regulator with a frictionless diaphragm improves set point stability across varying load and flow. Materials flexibility (PVC/316L/PTFE) enables compatibility from air to corrosives.
Routine leak checks and flow validations help maintain safety, reduce waste and support change control documentation. A portable, battery powered meter lets engineers verify lines, mass flow set ups and small leaks without installing permanent hardware. Multi gas capability simplifies use across different carriers and test gases. On board logging and USB/Bluetooth connectivity accelerate reporting.
Incubators, gloveboxes and sensor test rigs benefit from precise, programmable gas ratios with fast response to set point changes. Repeatable blend accuracy reduces waste and improves experimental consistency. Remote access and data logging simplify audit trails and R&D method development. The system should scale from benchtop SCCM levels to high flow box purges.
| Application | Recommended Technologies | Why It Helps |
|---|---|---|
| Bioreactor gas control & sparging | Alicat BIO Series MFCs | 10,000:1 control, 316L/USP VI, moisture tolerant; rapid integration and stable DO/CO₂ control. |
| Supercritical CO₂ scaffolds | Equilibar Supercritical BR BPRs | Frictionless, high pressure control with minimal hysteresis in scCO₂ regimes. |
| Media/buffer prep & transfer | Steriflow 978JD; Longer L600 1F | Hygienic, self draining valve; programmable dispensing/transfer with PLC connectivity. |
| Aseptic filling & micro dosing | FMI FENYX® | Valveless ceramic internals for repeatable sub µL to mL dosing with low maintenance. |
| Chromatography outlet BPR | Equilibar Research Series | Ultra stable back pressure at very low flows; broad materials/temperature options. |
| UF/DF (TFF) BPR | Equilibar Biopharm SD (single use) | Sterilizable disposable flow path with fast response for tight TMP control. |
| Clean steam (SIP/CIP) PRV | Steriflow Mark 96 | Sanitary pressure regulation with Jorlon diaphragm and full documentation. |
| WFI/PUW verification | Dynasonics TFX 5000 | Non intrusive clamp on flow/energy metering; no contamination or downtime. |
| UHP/calibration gas lines | Drastar 2200 UHP | Two stage stability; EP 316L/VAR with VCR® connections for low leakage. |
| Controlled atmospheres | Fusion Flow MXM | ±0.6% accuracy, 25ms response; 200 SCCM–50,000 SLPM and up to 10 channels |
| Lab vacuum/pressure control | Equilibar EVR | High resolution, frictionless vacuum regulation across sizes and materials |
| Leak testing & validation | Alicat MB Portable | Battery operation, multi gas library, and on board logging for quick audits |
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