Business

Biorreactor

A 90-minute, 4-round basic Express simulation for Spanish vocational training (Formacion Profesional), module 1393 Tecnicas de produccion biotecnologica of the Tecnico Superior en Fabricacion de Productos Farmaceuticos, Biotecnologicos y Afines (Real Decreto 832/2014).

4 rounds Undergraduate English, Español

Preview

About this simulation

A 90-minute, 4-round basic Express simulation for Spanish vocational training (Formacion Profesional), module 1393 Tecnicas de produccion biotecnologica of the Tecnico Superior en Fabricacion de Productos Farmaceuticos, Biotecnologicos y Afines (Real Decreto 832/2014).

The learner is Ainara Eransus, a newly qualified fermentation technician of a fictional enzyme plant, through 2027, at a stainless-steel fed-batch bioreactor in which a recombinant yeast makes a phytase, with sterilisation in place, sterile air filters, pH, dissolved-oxygen and temperature control, a foam probe, a feed pump, a sampling valve and a seed train from a working cell bank.

Four situations set the year's course: an air filter that fails its integrity test before an inoculation, and how sterility is checked (the record read and the filters tested, never an inoculation behind a failed test) and how the probes and the control are set (calibrated, the oxygen cascade by the batch record); foam at the exhaust and glucose piling up, and what is done with the foam (the cause first, antifoam dosed by the probe, the high-pressure interlock never bypassed) and how the feed is run (on the profile, raised on the oxygen and the glucose); the restart after the August stop, and how the seed train restarts (from the cell bank with purity checks) and how the sampling valve and the seals are run; and a night when the culture is contaminated, answered by inactivating the batch in the vessel and holding the next one, and how the year's events are recorded.

Three critical errors cap the round: an inoculation behind a failed filter test, the high-pressure interlock bypassed and the exhaust closed, a contaminated broth drained without inactivation. KPIs: production on specification, fermentation suite operating cost, culture lost a week and deviations and contaminations. Lesson: catching a contamination early is what saves the next batch. Spanish primary, English parity.

Fictional plant, companies and people; real curriculum cited.

What participants learn

After the session, participants will be able to:

  • Verify sterility before inoculating by reading the sterilisation record against the batch record, confirming the pressure hold and refusing to inoculate behind a failed filter integrity test
  • Calibrate the pH and dissolved-oxygen probes, check the pH against an off-line sample after sterilisation and set the oxygen cascade by the batch record, never pushing the feed beyond the oxygen
  • Diagnose the cause of foaming and dose antifoam by the probe within the batch record instead of bypassing the high-pressure interlock
  • Run the fed-batch feed on its profile, restart the seed train from the working cell bank with purity checks and maintain the sampling valve and its seals on a plan
  • Decide how to answer a confirmed contamination: stop the feed, inactivate the batch in the vessel, hold the next batch until the route is found and write a deviation report with its root cause

Prerequisites

  • Has run or watched a laboratory fermenter

Who it is for

An introductory simulation that assumes no prior knowledge of the subject, designed for undergraduate courses. It also works in vocational and high-school programmes and in onboarding sessions.

How a session runs

  1. The instructor creates a session from the Eureka dashboard and invites the participants.
  2. Participants play 4 rounds. In each one they submit their decisions and the simulation calculates the results. The first round opens with: lunes 11 de enero, 6:00: el filtro que falla y las sondas.
  3. The simulation can be run in English, Español.
  4. The instructor follows each participant's progress and results from the dashboard, and uses the class results for the debrief.

Decisions participants make

The decisions participants make during the simulation:

  • Cómo se comprueba la esterilidad antes de inocular
  • Cómo se preparan las sondas y el control
  • Qué se hace cuando la espuma llega a la salida
  • Cómo se lleva la alimentación
  • Cómo arranca el tren de inóculo
  • Cómo se llevan el muestreo y las juntas
  • Cómo se responde a una contaminación confirmada
  • Cómo se registran los sucesos del año

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