Scaling Single-Use Sensors for Bioprocessing Systems
From prototype to more than 1’000 units per month
An established biotech company contracted us to develop and industrialize highly reliable single-use pH and conductivity sensors. The sensors required a custom design to ensure seamless integration into the customer’s bioprocessing system while delivering high accuracy, consistent performance, and a clear path to scalable production.
What began as a small development project evolved into a long-term partnership that has continued for more than a decade. Working closely with the customer’s R&D team, we developed customized single-use sensors tailored to their bioprocessing systems. Each sensor was designed to deliver accurate measurements, batch-to-batch consistency, reliable performance, and straightforward integration into existing systems.
As the customer’s operations grew, sensor production grew with them. Manufacturing increased from approximately 10 sensors per month to more than 1’000 sensors per month while maintaining the same quality standards and product performance. Through scalable manufacturing processes, rigorous quality assurance, flexible production capabilities, and close technical collaboration, production was successfully increased by a factor of 100 without compromising reliability.
Key success factors included:
- scalable manufacturing processes
- flexible production capabilities
- rigorous quality assurance
- close technical collaboration
Today, after more than 10 years of continuous use, these custom single-use pH and conductivity sensors remain an integral part of the customer’s bioprocessing systems.