On pilot and production systems, the Talamus control unit runs the sterilisation in place (SIP), cooling and cultivation phases automatically. The process variables selected for the project are logged with time stamps. Authorised users can use defined manual operating functions; interlocks remain in force throughout. The control software and operator panel (HMI) are developed by Pikolab R&D.
Valve positions and control parameters are predefined for each phase. Phase transitions follow the permissive and interlock conditions defined during the project.
Plant steam is used for jacket heating, while the product-contact sterilisation in place (SIP) circuit uses steam of a quality suited to the process requirement. Steam distribution, condensate drainage, temperature measurement points, hold time and any required isolation or protection arrangements are defined within the project. SIP conditions are managed within equipment and sensor limits.
After sterilisation the vessel is cooled in a controlled manner through the jacket. During cooling the vessel is protected against vacuum and sterile conditions are maintained.
After inoculation, temperature, pH and dissolved oxygen are held at set point and level is monitored. Aeration is managed by mass-flow control, pH by acid and base peristaltic pumps and temperature by closed-loop jacket circulation.
On pilot and production systems, the Talamus control unit runs on an industrial PLC with PID-based loops. Each process phase has defined valve positions, active loops, permissives and alarm thresholds; the operator does not position valves one by one.
Optical DO sensor; configurable cascade control using mass-flow-controlled air supply and agitation speed.
Set points and phase sequences are defined on the control unit and changed only by authorised users.
Sensor and probe connections, pump status and PLC faults are monitored continuously. When a function cannot be performed or no data arrives from a sensor, a hardware alarm is raised and recorded in the event log.
Control loops rely on sensor measurements; sensor drift leads directly to control error. Ageing of the sensor cap on an optical DO probe or fouling of the reference junction on a pH electrode can cause a process that appears to be on set point to deviate from it.
In addition to standard pH, DO, temperature, level and pressure, process analytical technology (PAT) options such as in-line biomass/optical density, viscosity, foam, exhaust gas analysis and dissolved CO₂ can be added. We have been installing and calibrating these instruments in food, chemical and biotechnology plants since 2011. We also commission and recalibrate the measurement chain on Talamus systems with the same team.
QorSense is sensor and process analytics software developed by Pikolab R&D. We have begun integrating it into Talamus systems. QorSense tracks drift and noise in the raw sensor signal and derives sensor condition indicators. These indicators help set maintenance and calibration priorities and support operator decisions with process data. A patent application has been filed for the signal processing core.
The defined process variables are logged with time stamps on the control unit, can be backed up to external storage and are exported via USB flash drive or Ethernet. QorSense can run on site without a cloud connection. Where remote access, backup or a service connection is needed, we define its scope separately in the project.
The process variables, alarms and user actions selected for the project are logged with time stamps. Records are reviewed as charts and tables on the touch screen. Data are exported via USB flash drive or Ethernet and can be opened in data processing software on another computer. The file format is stated in the project documentation.
Up to 12 users at different authorisation levels are defined as standard; only authorised personnel can change control parameters. User actions are recorded and can be reported retrospectively.
High and low limit alarms per parameter and hardware alarms such as sensor communication loss are defined; the defined events are recorded in the log.
Authorised users can monitor the process over a configured local network or secure remote access. Remote control rights and network security are defined separately within the project.
We define phase sequences, control loops, data logging and remote access requirements at the start of the project.