Single-use (SU) technology is transforming biopharmaceutical manufacturing, replacing traditional stainless steel production tanks with flexible, scalable, and cost-effective solutions. Companies worldwide are investing in SU technology to streamline processes, reduce downtime, and allocate resources more efficiently; however, integrating traditional sensors into SU environments poses challenges. Fortunately, suppliers have responded and now offer an expanding array of purpose-built solutions: sensors ready to be seamlessly employed within the SU bag or vessel.

Biopharmaceutical companies worldwide are embracing single-use (SU) technology as a viable alternative to reusable stainless steel production tanks. This shift is driven by several key factors. First and foremost, SU technology offers enhanced flexibility and scalability, allowing manufacturers to adapt quickly to changing production demands. SU systems eliminate the need for extensive cleaning and sterilization processes associated with traditional stainless steel equipment, reducing downtime and speeding up overall production cycles. Furthermore, SU technology provides significant cost savings by eliminating the need for complex infrastructures, such as large-scale cleanrooms and extensive water purification systems. The reduction in capital expenditures associated with SU systems enables companies to allocate resources more efficiently and invest in research and development efforts.

Challenges with Reusable Sensors in Single-Use Environments

While SU technology presents compelling advantages, integrating reusable sensors into SU bags with the help of insertion devices can pose significant challenges for process engineers. Common concerns include the risk of contamination across batches and leakage at weak-points where the sensor connects, which diminishes the benefits of a SU process. Recognizing the necessity for dedicated sensors tailored to SU environments, Hamilton Process Analytics has developed a comprehensive range of SU sensors specifically designed to address these challenges. These sensors seamlessly integrate into SU systems through weld-in ports, ensuring accurate and reliable measurements while maintaining the highest standards of sterility.

The Need for Single-Use Sensors

As the biopharmaceutical industry continues to employ the benefits of SU technology, the demand for dedicated SU sensors becomes increasingly vital. Hamilton has been working closely with SU bag manufacturers, to be able to offer products with minimal integration efforts by using industry-standard port fittings. Hamilton’s SU sensors are delivered pre-calibrated and are then installed into SU bags and sterilized by the integrator. In this ready to use state, Hamilton sensors offers peace of mind to our end-users for a quick and clean start of production process.

As a major supplier of SU sensors, Hamilton offers sensors for pH, viable cell density, dissolved oxygen and conductivity measurement for integrator clients such as bag, vessels, and downstream skid manufacturers. Their SU sensors offer the same reliable technology of Hamilton’s reusable sensors in a convenient pre-calibrated, ready to use format where users can start immediately thanks to a simple “Scan and Go” code on the sensor. SU sensors are suitable for long-term dry storage (up to 24 months) and have a short wet-in time (< 30 minutes) when setting up the process. The SU sensors can be seamlessly integrated into the customer’s existing set-up as they are compatible with most common electrical interfaces. All Hamilton single-use products include the “Arc” intelligent sensor technology. “Arc” converts the measurement into a robust, noise-free digital signal without the need of traditional bulk transmitters. In contrast to conventional analog sensors, these intelligent sensors provide information about sensor health, enabling predictive maintenance and facilitating real-time remote monitoring of processes through wireless communication to Hamilton’s “ArcAir” software.


Product overview

Beeld: Hamilton

The current range of SU sensors available from Hamilton include:


Beeld: Hamilton

Factory Calibration Labels: Every single-use sensor comes with factory calibration data printed on the sensor tag. This data can be scanned into ArcAir with the 2D barcode, or directly entered into the bioreactor control system.

With a commitment to innovation, Hamilton will be showcasing its latest SU product innovations at the upcoming Single-Use event in Leiden, the Netherlands, in September.

If you’re already curious about Hamilton’s innovative offerings, visit Hamilton’s website to explore their cutting-edge technologies ahead of the event. Don’t miss the chance to experience the next generation of SU sensor advancements firsthand.