What is a biopharmaceutical? Key data and classification

Biopharmaceuticals (biological medicines) have become fundamental in modern medicine. Unlike traditional drugs synthesized chemically, biopharmaceuticals are derived from living organisms or biotechnological processes. Below, we answer several frequently asked questions on the topic.

What does biopharmaceuticals mean?

A biopharmaceutical is any pharmaceutical product whose active ingredient originates from a biological source (e.g., cells or tissues of living organisms). In other words, they are medicines derived from living beings or created through biotechnology.

These products include a wide range of substances such as therapeutic proteins (antibodies, hormones), vaccines, blood components (plasma, clotting factors), living cells used in cell therapies, and even genes used in gene therapy. Unlike conventional drugs (small chemical molecules), biopharmaceuticals are usually large and complex molecules (such as proteins or nucleic acids), or even entire cells. Therefore, they are not obtained through chemical synthesis but produced using biological systems (cell cultures, bacteria, yeasts, etc.). In summary, the term biopharmaceutical encompasses any medicine of biological origin, from a simple vaccine to advanced cell or gene therapies.

What is biopharmaceutical classification system?

The Biopharmaceutical Classification System (BCS) is a tool used in pharmacology to classify drugs based on their solubility and permeability. Proposed in 1995 by scientist Gordon Amidon, it predicts how a drug will be absorbed in the body when taken orally. This classification helps determine whether a drug will dissolve easily in the digestive tract and whether it can cross biological membranes to enter the bloodstream. The BCS defines four classes of drugs:

  • Class I: High permeability and high solubility – These drugs are easily absorbed; a typical example is propranolol.
  • Class II: High permeability and low solubility – They absorb well once dissolved, but have poor solubility; e.g., ibuprofen.
  • Class III: Low permeability and high solubility – They dissolve easily but have difficulty crossing membranes; e.g., ranitidine.
  • Class IV: Low permeability and low solubility – They have both poor dissolution and poor absorption; e.g., chlorothiazide.
Infographic explaining the Biopharmaceutical Classification System (BCS), dividing drugs into four classes based on solubility and permeability.

What is the use of this classification? 

Mainly, for regulatory and pharmaceutical development purposes. Knowing the BCS class of a drug allows for decisions such as whether a generic version can demonstrate efficacy with just lab dissolution tests rather than expensive human trials (called biowaivers). In short, the BCS links the physicochemical properties of a drug with its behavior in the body, aiding drug development and bioequivalence evaluation

What is a biopharmaceutical company?

A biopharmaceutical company is a pharmaceutical firm specialized in the research, development, and production of biological medicines (biopharmaceuticals) using biotechnological methods. Simply put, these companies use living organisms or their components (cells, genes, proteins) to create medicines. From an industrial standpoint, the biopharmaceutical industry is a subset of the broader pharmaceutical industry.

A company is considered biopharmaceutical when it employs biotechnology in its techniques and manufacturing processes. This includes both emerging biotech startups and large pharmaceutical companies with divisions dedicated to biologics.

They typically engage in genetic engineering to develop new products (e.g., inserting human genes into bacteria or mammalian cells to produce a therapeutic protein like insulin), cultivate these cells at scale, purify the resulting product, and conduct clinical trials to demonstrate safety and efficacy.

Is biopharma the same as pharma?

In everyday language, “pharma” refers to the pharmaceutical industry in general, while “biopharma” specifically refers to the biotechnological drug segment. They are not exactly the same, though they are closely related. As explained, biopharma is essentially a part of the broader pharma industry focused on innovative biological medicines, whereas pharma includes both traditional chemical drugs and biological drugs. In short, all biopharmaceutical companies are pharmaceutical companies, but not all pharmaceutical companies are biopharmaceutical.

What is the difference between biopharmaceuticals and traditional drugs?

Biopharmaceuticals (biological drugs) and traditional drugs (chemical medicines) differ in how they are made, what they are made of, and how they behave:

  • Origin and molecular size: Traditional drugs are small molecules produced through chemical synthesis in a lab, while biopharmaceuticals are larger and more complex substances derived from living organisms (e.g., proteins made of thousands of amino acids). Designing, characterizing, and producing a biopharmaceutical is much more complex and expensive than a simple drug. There’s also some variability between batches of biopharmaceuticals, as no two living cells produce proteins exactly the same way, unlike with simple chemical molecules. For example, aspirin (a traditional drug) is made through a well-defined chemical process always yielding the same molecule, while recombinant insulin (a biopharmaceutical) involves living cells and tight process control to maintain consistency.
  • Production: Traditional drugs are synthesized by mixing chemical reagents. In contrast, biopharmaceuticals are “grown.” A human or animal gene is inserted into a microorganism or cell line, and those cells produce the drug. Then it must be purified from among many other biological components. For example, insulin was originally extracted from animal pancreases, but modern insulin is made by inserting the human insulin gene into bacteria, which produce it in fermentation tanks. This biological process is much more delicate and must be done under strict sterile conditions.
  • Copies or generics: Due to their complexity, biopharmaceuticals cannot be copied exactly like chemical drugs. When the patent for a chemical drug expires, companies can make an identical copy called a generic. But when a biopharmaceutical’s patent expires, it’s impossible to make an exact molecular copy; instead, companies develop biosimilars, which are highly similar versions, not identical. Biosimilars must undergo additional studies to prove they perform like the original biopharmaceutical. In contrast, a chemical generic only needs to prove it contains the same molecule and absorbs similarly.
  • Immunogenicity and administration: Since biopharmaceuticals are proteins or cells, they may trigger immune responses (the body may recognize them as foreign). This requires monitoring for allergies or resistance (anti-drug antibodies). Traditional drugs rarely provoke complex immune reactions. Also, administration routes differ: biopharmaceuticals are usually not given orally, as digestive enzymes would destroy them, they are administered by injection or intravenous infusion. Many traditional drugs come as tablets or capsules taken orally (e.g., antibiotics or painkillers). Additionally, biopharmaceuticals often require cold storage for stability (like vaccines), while chemical drugs are typically stable at room temperature.

In summary, biopharmaceuticals are much more complex in composition and manufacturing, are produced by living cells, and require special considerations for use. Traditional drugs are simpler chemical molecules, synthesized in labs, and can be copied exactly. Both have transformed medicine, each with its own advantages and challenges.

Comparison between biopharmaceuticals and traditional drugs
AspectBiopharmaceuticalsTraditional Drugs
Origin & Molecular SizeLarge, complex molecules (e.g., proteins) from living organisms; variability between batches.Small, simple molecules made by chemical synthesis; consistent across batches.
ProductionGrown using genetically modified cells; requires sterile cultivation and purification.Synthesized by mixing chemical reagents in a lab.
Copies or GenericsCannot be exactly copied; biosimilars are developed and require additional validation.Can be exactly copied as generics; require only bioequivalence studies.
Immunogenicity & AdministrationMay trigger immune responses; administered by injection or infusion, not orally.Rarely cause immune reactions; typically administered orally (tablets, capsules).
StorageOften requires cold storage to maintain stability (e.g., vaccines).Usually stable at room temperature.
Overall ComplexityHigh complexity in design, manufacturing, and regulation.Lower complexity; simpler and cheaper to produce and regulate.

What is considered a biopharmaceutical?

The term biopharmaceutical includes a wide variety of therapeutic products of biological origin. In general, any medicine whose active component comes from a living organism or from the biotechnological manipulation of one is considered a biopharmaceutical. Here are some representative examples:

  • Vaccines: Biological preparations that stimulate immunity to prevent infectious diseases. For example, the hepatitis B vaccine (produced using recombinant DNA in yeast cells) or mRNA vaccines for COVID-19, which use genetic instructions to prompt our cells to produce a viral protein and trigger an immune response. Vaccines are considered biopharmaceuticals because they are obtained from attenuated or inactivated viruses, or through cell culture.
  • Monoclonal antibodies: Lab-designed immune system proteins that bind specifically to a target (antigen). They are used in cancer treatments (e.g., trastuzumab for breast cancer), autoimmune diseases (e.g., adalimumab for rheumatoid arthritis), and other conditions. Since they originate from cells (typically genetically modified Chinese hamster ovary cells or similar), they fall under the biopharmaceutical category.
  • Recombinant hormones and proteins: Many human hormones used as medicines are now biotechnologically produced. Classic examples: recombinant insulin for diabetes (previously obtained from pig pancreases, now produced in modified bacteria), erythropoietin (EPO) to treat anemia, or human growth hormone for growth disorders. These are molecules naturally produced by the body, but as medicines, they are manufactured using genetic engineering in living cells.
  • Blood derivatives and human/animal-based products: This includes medicines obtained directly from tissues or biological fluids. Examples: plasma-derived clotting factors for hemophilia, immunoglobulins (polyclonal antibodies) from donors for immunodeficiencies, or even cell and tissue transplants (like bone marrow transplants or stem cell therapies). Historically, many of these came from animals or human donors. A curious example: insulin used to be extracted from animal pancreases, and antivenom serum is produced by immunizing horses to obtain antibodies against snake venom, a biological process. All of these are biopharmaceuticals because their active ingredients come from living organisms.
  • Advanced gene and cell therapies: In one of the most innovative medical fields, gene therapies (introducing functional genetic material to correct diseases) and cell therapies (like CAR-T therapy for leukemia, where a patient’s T cells are genetically modified) are considered biopharmaceuticals. For instance, Luxturna is a gene therapy approved for a type of inherited blindness; it uses a modified virus to deliver a functional gene into a patient's eye. Although these are not “traditional” pills, they are regulated as biological drugs and therefore fall under the biopharmaceutical umbrella.

In summary, a biopharmaceutical is any medicine that uses biological or biotechnological agents as the basis for its therapeutic effect. From vaccines to monoclonal antibodies or modified cells, they all share a biological origin. This broad definition is supported by agencies like the EMA and FDA. For example, the European Medicines Agency (EMA) defines a biological medicine as one whose active substance is produced by or derived from a living organism.

Infographic showing the CRISPR-Cas9 process: guide RNA targets a DNA sequence, Cas9 enzyme cuts it, and the cell repairs the gene.

What are the four categories of biopharmaceutical products?

The main classification of biopharmaceuticals typically distinguishes four broad categories based on their origin and nature:

  • Extracts from living organisms: These are the oldest biological products, obtained directly from living sources (human or animal) without genetic modification. They include blood components (blood, plasma, clotting factors), polyclonal antibodies from serum (e.g., antitoxins for venom), hormones or enzymes extracted from animal tissues, organ and tissue transplants, and even therapeutic uses of breast milk or fecal microbiota. These extracts were the first “biological medicines.” A classic example is insulin extracted from bovine or porcine pancreas before the advent of genetic engineering.
  • Products obtained through recombinant DNA: These are modern biopharmaceuticals made using genetic biotechnology. This category includes most therapeutic proteins created by cloning human genes into microorganisms or cultured cells. Examples include:
    • Recombinant hormones and cytokines: Such as human insulin, erythropoietin, growth hormone, interferons, and growth factors, produced in bacteria or other cells with inserted human genes.
    • Monoclonal antibodies: Although also proteins, these are often highlighted due to their significance. They are produced using hybridoma technology or genetically modified cells that secrete a specific antibody (e.g., rituximab, infliximab).
    • Fusion proteins and constructs: Such as soluble receptors fused to antibody fragments (e.g., etanercept, a TNF receptor fused to an antibody’s Fc portion).

All of these are manufactured in bioreactors using transgenic cells and represent a large share of today’s biopharmaceuticals.

  • Vaccines: Vaccines form a standalone category due to their major public health role. Most vaccines are made by growing viruses, bacteria, or cells in special media, then inactivating or attenuating them, or extracting components (antigens) to trigger immunity. Recombinant vaccines also exist, only the relevant protein is produced in the lab (e.g., the hepatitis B vaccine uses yeast to produce the virus’s surface protein). Recently, nucleic acid vaccines (DNA or mRNA, like COVID-19 vaccines) have also emerged, and these are also considered biopharmaceuticals. In short, all vaccines, traditional or next-gen, are biopharmaceuticals, as their production relies on biological processes (cell culture, genetic engineering, etc.).
  • Gene and cell therapies: This category includes treatments in which the therapeutic agent is genetic material or modified cells, rather than a conventional protein or molecule. In typical gene therapy, a modified viral vector is used to introduce a functional gene into a patient’s cells that carry a defective one. By manipulating the genome of viruses and cells, very unique “medicines” are created. This category also includes cell therapies, such as stem cell infusions or CAR-T treatments (genetically modified T cells from the patient). These advanced therapies are regulated as biopharmaceuticals by agencies and require rigorous evaluations.

In conclusion, biopharmaceuticals can be classified into traditional biological extracts, recombinant products (proteins/antibodies), vaccines, and gene/cell therapies. Each category reflects a different mode of production and type of therapeutic agent, but they all share the common feature of being derived from biology. This classification helps us understand the wide range of biopharmaceuticals available, from the most “classic” (like blood or insulin) to the most innovative (like gene vectors or modified cells).

How are biopharmaceuticals developed and produced?

Creating a biopharmaceutical is a complex process that combines biology, engineering, and strict quality control. The main stages are:

  1. Research and genetic design: First, the desired therapeutic molecule is identified (e.g., a gene encoding a beneficial human protein or a specific antibody). Scientists isolate or synthesize the gene and insert it into a vector (like a DNA plasmid). This vector is used to introduce the gene into host cells (bacteria, yeast, or mammalian cells). Essentially, a production organism is “designed” through genetic modification. For example, to produce human insulin, the insulin gene is inserted into E. coli bacteria.
  2. Cell culture (bioproduction): Once the genetically modified cell line is created to produce the biopharmaceutical, it is cultivated at scale. Bioreactors, special tanks, are used to maintain optimal conditions for the cells to grow and produce the desired protein or product. These tanks range from small lab-scale units (a few liters) to industrial facilities holding thousands of liters.
  3. Recovery and purification: After cultivation, the culture broth contains a complex mix (cells, nutrients, waste products, and the produced biopharmaceutical). The next step is to extract and purify the biopharmaceutical. Advanced separation techniques are used: filtration, chromatography (which separates molecules by chemical properties), centrifugation, etc. The goal is to isolate the active protein or product at high purity, removing contaminants (such as cell debris, DNA, or other proteins). This is critical, biopharmaceuticals require extreme purity, as even minimal impurities can cause adverse reactions in patients. For monoclonal antibodies, multiple chromatography steps are performed to achieve near 100% purity. For cell therapies, “purification” might mean selecting and concentrating the desired cells while removing non-viable ones.
  4. Formulation and quality control: Once purified, the active ingredient is formulated into a suitable pharmaceutical form (e.g., lyophilized and later reconstituted, or mixed with stabilizers). Throughout the process, stringent quality controls are in place. The identity of the molecule is confirmed (ensuring it is the correct protein with the proper 3D structure), its biological activity is verified, its purity is measured, and potential contaminants (microbial, viral, endotoxins, residual DNA, etc.) are checked. Due to their complexity, biopharmaceuticals undergo far more extensive testing than chemical drugs.
  5. Clinical trials and regulatory approval: Alongside pilot-scale production, the biopharmaceutical must demonstrate safety and efficacy in human clinical trials. These usually occur in phases (I, II, III), like with any drug. However, additional studies may be required for biopharmaceuticals, such as immunogenicity assessments (checking for unwanted immune responses) or comparability studies if manufacturing changes occur. Finally, regulatory agencies (FDA in the U.S., EMA in Europe, etc.) evaluate all data. Biopharmaceuticals are subject to strict regulations: manufacturing facilities must comply with Good Manufacturing Practices (GMP), and any process changes must be reported.

Once a biopharmaceutical passes these tests, it is approved for marketing. Even after approval, it continues to be monitored (pharmacovigilance), and each batch undergoes control tests before distribution. A key point: due to the complexity of production, biopharmaceuticals tend to be expensive, though prices tend to drop over time with the arrival of biosimilars.

Conclusion

Biopharmaceuticals represent the intersection of biology and pharmacy. We’ve seen what they are, how they are classified, and how they differ from traditional drugs. We’ve also explored examples (from insulin and vaccines to monoclonal antibodies) and summarized how they are taken from the lab to the patient via cell culture and regulatory processes. Understanding these concepts helps us appreciate how advances in genetics and biotechnology translate into new medical treatments. Biopharmaceuticals are already part of our lives, and in the future, we’ll likely see even more innovative biological therapies tackling diseases once thought incurable.

What is a biopharmaceutical? Key data and classification

Frequently Asked Questions (FAQ)

1. What is a biopharmaceutical?

It’s a drug produced using living cells or organisms, usually proteins or nucleic acids.

2. How are biopharmaceuticals different from traditional drugs?

They’re biologically derived, while traditional drugs are chemically synthesized.

3. What are biopharmaceuticals used for??

They treat diseases like cancer, autoimmune disorders, and genetic conditions.

4. How are biopharmaceuticals manufactured?

Through complex processes like cell culture, fermentation, purification, and formulation.

5. What are examples of biopharmaceutical products?

Insulin, erythropoietin, monoclonal antibodies, and mRNA vaccines.

References

Subscribe to our newsletter

Newsletter Form

Contact form

Your opinion is very important to us, and we encourage you to contact our sales team to discuss the purchase of our bioprocess equipment. We are here to answer your questions and help you find the best solution for your needs.

Quote
Related Content

Quote

Quote
Image to access to all TECNIC's features, you can see a person working with the ePilot Bioreactor.

Coming soon 

We are finalizing the details of our new equipment. Soon, we will announce all the updates. If you want to receive all the latest news about our products, subscribe to our newsletter or follow our social media channels. 

Newsletter Form

Sign Up

Stay informed about our product innovations, best practices, exciting events and much more! After signing up for our newsletter, you can unsubscribe at any time.

Newsletter Form

Cassette

We understand the importance of flexibility and efficiency in laboratory processes. That's why our equipment is designed to be compatible with Cassette filters, an advanced solution for a variety of filtration applications. Although we do not manufacture the filters directly, our systems are optimized to take full advantage of the benefits that Cassette filters offer.

Cassette filters are known for their high filtration capacity and efficiency in separation, making them ideal for ultrafiltration, microfiltration, and nanofiltration applications. By integrating these filters into our equipment, we facilitate faster and more effective processes, ensuring high-quality results.

Our equipment, being compatible with Cassette filters, offers greater versatility and adaptability. This means you can choose the filter that best suits your specific needs, ensuring that each experiment or production process is carried out with maximum efficiency and precision.

Moreover, our equipment stands out for its 100% automation capabilities. Utilizing advanced proportional valves, we ensure precise control over differential pressure, transmembrane pressure, and flow rate. This automation not only enhances the efficiency and accuracy of the filtration process but also significantly reduces manual intervention, making our systems highly reliable and user-friendly.

Hollow Fiber

We recognize the crucial role of flexibility and efficiency in laboratory processes. That's why our equipment is meticulously designed to be compatible with Hollow Fiber filters, providing an advanced solution for a broad spectrum of filtration applications. While we don't directly manufacture these filters, our systems are finely tuned to harness the full potential of Hollow Fiber filters.

Hollow Fiber filters are renowned for their exceptional performance in terms of filtration efficiency and capacity. They are particularly effective for applications requiring gentle handling of samples, such as in cell culture and sensitive biomolecular processes. By integrating these filters with our equipment, we enable more efficient, faster, and higher-quality filtration processes.

What sets our equipment apart is its 100% automation capability. Through the use of sophisticated proportional valves, our systems achieve meticulous control over differential pressure, transmembrane pressure, and flow rate. This level of automation not only boosts the efficiency and precision of the filtration process but also significantly diminishes the need for manual oversight, rendering our systems exceptionally reliable and user-friendly.

Contact General

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Microbial configuration

The microbial configuration of the eLab Advanced is equipped with a Rushton turbine specifically designed for high-oxygen-demand processes such as bacterial and yeast fermentations. The radial-flow impeller generates strong mixing and intense gas dispersion, promoting high oxygen transfer rates and fast homogenization of nutrients, antifoam and pH control agents throughout the vessel. This makes it particularly suitable for robust microbial strains operating at elevated agitation speeds and aeration rates.

Operators can adjust agitation and gas flow to reach the required kLa while maintaining consistent mixing times, even at high cell densities. This configuration is an excellent option for users who need a powerful, reliable platform to develop and optimize microbial processes before transferring them to pilot or production scales.

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Technical specifications

Materials and finishes

Typical
  • Product-contact parts: AISI 316L (1.4404), typical Ra < 0.4 µm (16 µin)
  • Non-contact parts/skid: AISI 304/304L
  • Seals/elastomers: platinum-cured silicone, EPDM and/or PTFE (material set depends on selection)
  • Elastomers compliance (depending on selected materials): FDA 21 CFR 177.2600 and USP Class VI
  • Surface treatments: degreasing, pickling and passivation (ASTM A380 and ASTM A968)
  • Roughness control on product-contact surfaces

Design conditions

Pressure & temperature

Defined considering non-hazardous process fluids (PED group 2) and jacket steam/superheated water (PED group 5), depending on configuration and project scope.

Reference design envelope
ModeElementWorking pressure (bar[g])Working pressure (psi[g])T max (°C / °F)
ProcessVessel0 / +2.50 / +36.3+90 / 194
ProcessJacket0 / +3.80 / +55.1+90 / 194
SterilisationVessel0 / +2.50 / +36.3+130 / 266
SterilisationJacket0 / +3.80 / +55.1+150 / 302
Jacket working pressure may also be specified as 0 / +4 bar(g) (0 / +58.0 psi[g]) depending on design selection; final values are confirmed per project.

Pressure control and safeguards

Typical
  • Designed to maintain a vessel pressure set-point typically in the range 0 to 2.5 bar(g)
  • Aseptic operation commonly around 0.2 to 0.5 bar(g) to keep the vessel slightly pressurised
  • Overpressure/underpressure safeguards included per configuration and regulations
  • Pressure safety device (e.g., rupture disc and/or safety valve) included according to configuration

Agitation

Reference ranges
Working volumeMU (Cell culture), referenceMB (Microbial), reference
10 L0 to 300 rpm0 to 1000 rpm
20 L0 to 250 rpm0 to 1000 rpm
30 L0 to 200 rpm0 to 1000 rpm
50 L0 to 180 rpm0 to 1000 rpm

Integrated peristaltic pumps (additions)

Typical

The equipment typically includes 4 integrated variable-speed peristaltic pumps for sterile additions (acid/base/antifoam/feeds). Actual flow depends on selected tubing and calibration.

ParameterTypical valueNotes
Quantity4 units (integrated)In control tower; assignment defined by configuration
Speed0-300 rpmVariable control from eSCADA
Minimum flow0-10 mL/minExample with 0.8 mm ID tubing; depends on tubing and calibration
Maximum flowUp to ~366 mL/minExample with 4.8 mm ID tubing; actual flow depends on calibration
Operating modesOFF / AUTO / MANUAL / PROFILEAUTO typically associated to pH/DO/foam loops or recipe
FunctionsPURGE, calibration, totaliser, PWMPWM available for low flow setpoints below minimum operating level

Gas flow control (microbial reference capacity)

Reference

For microbial culture (MB), gas flow controllers (MFC) are typically sized based on VVM targets. Typical reference VVM range: 0.5-1.5 (to be confirmed by process).

Working volume (L)VVM minVVM maxAir (L/min)O2 (10%) (L/min)CO2 (20%) (L/min)N2 (10%) (L/min)
100.51.55-150.5-1.51-30.5-1.5
200.51.510-301-32-61-3
300.51.515-451.5-4.53-91.5-4.5
500.51.525-752.5-7.55-152.5-7.5
O2/CO2/N2 values are shown as reference capacities for typical gas blending strategies (10% O2, 20% CO2, 10% N2). Final gas list and ranges depend on process and configuration.

Instrumentation and sensors

Typical

Instrumentation is configurable. The following list describes typical sensors integrated in standard configurations, plus common optional PAT sensors.

Variable / functionTypical technology / interfaceStatus (STD/OPT)
Temperature (process/jacket)Pt100 class A RTDSTD
Pressure (vessel/lines)Pressure transmitter (4-20 mA / digital)STD
Level (working volume)Adjustable probeSTD
pHDigital pH sensor (ARC or equivalent)STD
DO (pO2)Digital optical DO sensor (ARC or equivalent)STD
FoamConductive/capacitive foam sensorSTD
Weight / mass balanceLoad cell (integrated in skid)STD
pCO2Digital pCO2 sensor (ARC or equivalent)OPT
Biomass (permittivity)In-line or in-vessel sensorOPT
VCD / TCDIn-situ cell density sensorsOPT (MU)
Off-gas (O2/CO2)Gas analyser for OUR/CEROPT
ORP / RedoxDigital ORPOPT
Glucose / LactatePAT sensorOPT

Automation, software and connectivity

Typical

The platform incorporates TECNIC eSCADA (typically eSCADA Advanced for ePILOT) to operate actuators and control loops, execute recipes and manage process data.

Main software functions
  • Main overview screen with process parameters and trends
  • Alarm management (real-time alarms and historical log) with acknowledgement and comment option
  • Manual/automatic modes for actuators and control loops
  • Recipe management with phases and transitions; parameter profiles (multi-step) for pumps and setpoints
  • Data logging with configurable period and export to CSV; PDF report generation
Common control loops
  • Temperature control (jacket heating/cooling)
  • Pressure control (headspace) with associated valve management
  • pH control via acid/base addition pumps and optional CO2 strategy
  • DO control with cascade strategies (agitation, air, O2, N2) depending on package and configuration
  • Foam control (foam sensor and automatic antifoam addition)
Data integrity and 21 CFR Part 11

Support for 21 CFR Part 11 / EU GMP Annex 11 is configuration- and project-dependent and requires customer procedures and validation (CSV).

Utilities

Reference

Utilities depend on final configuration (e.g., AutoSIP vs External SIP) and destination market (EU vs North America). The following values are typical reference points.

UtilityTypical service / configurationPressureFlow / powerNotes
ElectricalEU base: 400 VAC / 50 Hz (3~)N/AAutoSIP: 12 kW; External SIP: 5 kWNA option: 480 VAC / 60 Hz; cabinet/wiring per NEC/NFPA 70; UL/CSA as required
Process gasesAir / O2 / CO2 / N2Up to 2.5 bar(g) (36.3 psi)According to setpointTypical OD10 pneumatic connections; final list depends on package
Instrument airPneumatic valvesUp to 6 bar(g) (87.0 psi)N/ADry/filtered air recommended
Cooling waterJacket cooling water2 bar(g) (29.0 psi)25 L/min (6.6 gpm)6-10 °C (43-50 °F) typical
Cooling waterCondenser cooling water2 bar(g) (29.0 psi)1 L/min (0.26 gpm)6-10 °C (43-50 °F) typical
Steam (External SIP)Industrial steam2-3 bar(g) (29.0-43.5 psi)30 kg/h (66 lb/h)For SIP sequences
Steam (External SIP)Clean steam1.5 bar(g) (21.8 psi)8 kg/h (18 lb/h)Depending on plant strategy

Compliance and deliverables

Typical

Depending on destination and project scope, the regulatory basis may include European Directives (CE) and/or North American codes. The exact list is confirmed per project and stated in the Declaration(s) of Conformity when applicable.

ScopeEU (typical references)North America (typical references)
Pressure equipmentPED 2014/68/EUASME BPVC Section VIII (where applicable)
Hygienic designHygienic design good practicesASME BPE (reference for bioprocessing)
Machine safetyMachinery: 2006/42/EC (until 13/01/2027) / (EU) 2023/1230OSHA expectations; NFPA 79 (industrial machinery) - project dependent
Electrical / EMCLVD 2014/35/EU; EMC 2014/30/EUNEC/NFPA 70; UL/CSA components and marking as required
Materials contactEC 1935/2004 + EC 2023/2006 (GMP for materials) where applicableFDA 21 CFR (e.g., 177.2600 for elastomers) - materials compliance
Software / CSVEU GMP Annex 11 (if applicable)21 CFR Part 11 (if applicable)
Standard documentation package
  • User manual and basic operating instructions
  • P&ID / layout drawings as per project scope
  • Material certificates and finish/treatment certificates (scope dependent)
  • FAT report (if included in contract)
Optional qualification and commissioning services
  • SAT (Site Acceptance Test)
  • IQ / OQ documentation and/or execution (scope agreed with customer)
  • CSV support package for regulated environments (ALCOA+ considerations, backups, time synchronisation, etc.)

Ordering and configuration

Project-based

ePILOT BR is configured per project. To define the right MU/MB package, volumes and options (utilities, sensors, software and compliance), please contact TECNIC with your URS or request the configuration questionnaire.

The information provided above is for general reference only and may be modified, updated or discontinued at any time without prior notice. Values and specifications are indicative and may vary depending on project scope, configuration and applicable requirements. This content does not constitute a binding offer, warranty, or contractual commitment. Any final specifications, deliverables and acceptance criteria will be confirmed in the corresponding quotation, technical documentation and/or contract documents.

Cellular configuration

The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

Technical specifications

    ePILOT BR configuration questionnaire









    Project details



















    FAT:

    Shipment:

    Installation:

    SAT:

    IQ/OQ:


    Process and automation requirements























    MU only (cell culture)


    MB only (microbial)


    Utilities and infrastructure



    North America specific















    Connections, consumables and compliance












    EU specific




    North America specific


    Software / CSV (GMP)


    Validation, testing and documentation










    GMP / CSV


    Logistics and installation











    Additional comments




    Cellular configuration

    The cellular configuration of the eLab Advanced is equipped with a pitched-blade impeller designed to support efficient mixing for cell culture processes in both laboratory development and early scale-up. The blade geometry promotes mainly axial flow, helping to distribute gases, nutrients and pH control agents uniformly throughout the vessel while keeping shear stress at a moderate level. This makes it suitable for mammalian, insect and other shear-sensitive cell lines when operated with appropriate agitation and aeration settings. In combination with the vessel aspect ratio and baffle design, the pitched blade supports stable foaming behavior and reproducible oxygen transfer, which is essential when comparing batches or transferring processes between working volumes.

    Operators can fine-tune agitation speed to balance oxygen demand and mixing time without excessively increasing mechanical stress on the culture. 

    Technical specifications

    Models and working volumes

    Tank

    The ePlus Mixer platform combines an ePlus Mixer control tower with Tank frames and eBag 3D consumables. Tank can be supplied in square or cylindrical configurations (depending on project) to match the bag format.

    Tank modelNominal volumeMinimum volume to start agitation*
    Tank 50 L50 L15 L
    Tank 100 L100 L20 L
    Tank 200 L200 L30 L
    Tank 500 L500 L55 L
    *Values based on agitation start interlocks per tank model. Final performance depends on the selected eBag 3D, fluid properties and configuration.

    Design conditions and operating limits

    Reference

    Reference limits are defined for the ePlus Mixer and the Tank. It is recommended to validate the specific limits of the selected eBag 3D and single-use sensors for the customer’s process.

    ElementOperating pressureMaximum pressure (safety)Maximum working temperature
    ePlus Mixer (control tower)ATM0.5 bar(g)90 °C
    TankATM0.5 bar(g)45 °C
    Jacket (if applicable)N/A1.5 barDepends on utilities / scope
    The 0.5 bar(g) limit is associated with the equipment design, the circuit is protected by a safety valve. Confirm final limits on the equipment nameplate and project specification.

    Materials and finishes

    Typical
    • Control tower housing and frame: stainless steel 304
    • Product-contact metallic hard parts (if applicable): stainless steel 316 (defined in project manufacturing documentation)
    • Non-product-contact metallic parts: stainless steel 304
    • eBag consumable: single-use polymer (supplier dependent, gamma irradiation / sterilisation per specification)
    • Vent filters: PP (polypropylene), per component list
    For GMP projects, the recommended documentation package includes material certificates, surface finish certificates (Ra if applicable) and consumable sterility/irradiation certificates.

    Agitation system

    Magnetic

    Non-invasive magnetic agitation, the impeller is integrated in the eBag 3D Mixer format, avoiding mechanical seals. Agitation speed is controlled from the HMI, with start interlocks linked to the tank model and minimum volume.

    Reference speed range
    • Typical agitation range: 120 to 300 rpm (configuration dependent)
    • Magnetic drive motor (reference): Sterimixer SMA 85/140, 50 Hz, 230/400 V, 0.18 kW
    • Gear reduction (reference): 1:5
    • Actuation (reference): linear actuator LEYG25MA, stroke 30–300 mm, speed 18–500 mm/s (for positioning)
    Final rpm and mixing performance depend on tank size, bag format and process requirements.

    Weighing and volume control

    Integrated

    Weight and derived volume control are performed using 4 load cells integrated in the tank frame legs and a weight indicator. Tare functions are managed from the HMI to support preparation steps and additions by mass.

    ComponentReference modelKey parameters
    Load cells (x4)Mettler Toledo SWB505 (stainless steel)550 kg each, output 2 mV/V, IP66
    Weight indicatorMettler Toledo IND360 DINAcquisition and HMI display, tare and “clear last tare”
    For installation engineering, total floor load should consider product mass + equipment mass + margin (recommended ≥ 20%).

    Pumps and fluid handling

    Standard

    The platform includes integrated pumps for additions and circulation. Final tubing selection and calibration define the usable flow range.

    Included pumps (reference)
    • 3 integrated peristaltic pumps for additions (acid/base/media), with speed control from HMI
    • 1 integrated centrifugal pump for circulation / transfer (DN25)
    Peristaltic pumps (reference)
    ParameterReferenceNotes
    Quantity3 unitsIntegrated in the control tower
    Pump headHYB101 (Hygiaflex)Example tubing: ID 4.8 mm, wall 1.6 mm
    Max speed300 rpmSpeed control reference: 0–5 V
    Max flow (example)365.69 mL/minDepends on tubing and calibration
    Centrifugal pump (reference)
    ParameterReference
    ModelEBARA MR S DN25
    Power0.75 kW
    FlowUp to 42 L/min
    PressureUp to 1 bar
    For circulation and sensor loops, the eBag 3D format can include dedicated ports (depending on the selected consumable and application).

    Thermal management (optional jacket)

    Optional

    Tank can be supplied with a jacket (single or double jacket options). The thermal circuit includes control elements and a heat exchanger, enabling temperature conditioning depending on utilities and project scope.

    • Jacket maximum pressure (reference): 1.5 bar
    • Thermal circuit safety: pressure regulator and safety valve (reference set-point 0.5 bar(g))
    • Heat exchanger (reference): T5-BFG, 12 plates, alloy 316, 0.5 mm, NBRP
    • Solenoid valves (reference): SMC VXZ262LGK, 1", DC 24 V, 10.5 W
    • Jacket sequences: fill / empty / flush (scope dependent)
    The tank maximum temperature may depend on the thermal circuit and consumable limits. Confirm final values with the selected eBag 3D specification.

    Instrumentation and sensors

    Optional SU

    Single-use sensors can be integrated via dedicated modules. The following references describe typical sensors and interfaces listed in the datasheet.

    VariableReference modelInterface / protocolSupplyOperating temperatureIP
    pHOneFerm Arc pH VP 70 NTC (SU)Arc Module SU pH, Modbus RTU7–30 VDC5–50 °CIP67
    ConductivityConducell-P SU (SU)Arc Module Cond-P SU, Modbus RTU7–30 VDC0–60 °CIP64
    TemperaturePt100 ø4 × 52 mm, M8 (non-invasive)Analog / acquisition moduleProject dependentProject dependentProject dependent
    Measurement ranges and final sensor list depend on the selected single-use components and project scope.

    Automation, software and data

    Standard + options

    The ePlus SUM control tower integrates an industrial PLC and touch HMI. Standard operation supports Manual / Automatic / Profile modes, with optional recipe execution depending on selected software scope.

    Software scope (reference)
    • Standard: eBASIC (base HMI functions)
    • Optional: eSCADA Basic or eSCADA Advanced (project dependent)
    • Trends, alarms and profiles, profiles up to 100 steps (depending on scope)
    • Data retention (reference): up to 1 year
    Connectivity (reference)
    • Industrial Ethernet and integrated OPC server (included)
    • Remote access option (project dependent)

    Utilities and facility interfaces

    Typical

    Installation requirements depend on jacket and temperature scope and the customer layout. The following values are typical references.

    UtilityPressureFlowConnectionsNotes
    Electrical supplyN/AReference: 18 A380–400 VAC, 3~ + N, 50 HzConfirm per final configuration and destination market
    EthernetN/AN/ARJ45OPC server, LAN integration
    Tap water2.5 barN/A1/2" (hose connection)Jacket fill and services, tank volume about 25 L
    Cooling water2–4 bar10–20 L/min2 × 3/4" (hose connection)Heat exchanger and jacket cooling
    Process air2–4 barN/A1/2" quick couplingUsed for jacket emptying
    DrainN/AN/A2 × 3/4" (hose connection)For draining
    ExhaustN/AN/AN/AOptional (depending on project)
    Stack light (optional)N/AN/AN/A3-colour indication, as per scope
    During FAT, verify in the installation checklist that the available utilities match the selected configuration and scope.

    Documentation and deliverables

    Project-based

    Deliverables depend on scope and project requirements. The following items are typical references included in the technical documentation package.

    • Datasheet and user manual (HMI and system operation)
    • Electrical schematics, PLC program and backup package (scope dependent)
    • P&ID, layout and GA drawings (PDF and/or CAD formats, project dependent)
    • Factory Acceptance Test (FAT) protocol and FAT report (as per contract)
    • Installation checklist
    • Material and consumable certificates, as required for regulated projects (scope dependent)
    On-site services (SAT, IQ/OQ) and extended compliance packages are optional and defined per project.

    Ordering and configuration

    Contact

    The ePlus Mixer scope is defined per project. To select the right tank size, bag format, sensors and optional jacket and software, please share your URS or request the configuration questionnaire.

    The information provided above is for general reference only and may be modified, updated or discontinued at any time without prior notice. Values and specifications are indicative and may vary depending on project scope, configuration and applicable requirements. This content does not constitute a binding offer, warranty, or contractual commitment. Any final specifications, deliverables and acceptance criteria will be confirmed in the corresponding quotation, technical documentation and/or contract documents.