In an interview with News Medical, Yavuz Çelik, Global Product Manager at Hamilton Process Analytics, discussed the benefits of real-time cell density monitoring for biopharmaceutical production. Çelik highlighted that his work centers on developing technologies like the Incyte Arc and Dencytee Arc sensors, which are designed to provide real-time data on viable and total cell density in various bioreactor systems.
Çelik explained the functionality of the two main sensor platforms: “Incyte Arc uses biocapacitance spectroscopy. It creates an electromagnetic field using four platinum electrodes. Living cells with intact membranes become polarized and carry charge, which we measure to determine viable cell concentration. Dead cells do not respond because their membranes are compromised.”
Regarding the Dencytee Arc, he said: “Dencytee Arc combines transmission and reflection measurements. At lower turbidities, it measures transmitted light; as cell density increases and the medium becomes more opaque, it switches to reflection. This dual principle gives a broad, accurate range of measurement across all cell concentrations.”
Hamilton has also tested its sensors for use in space applications. Çelik noted: “At the University of Bremen, scientists tested Dencytee Arc in experiments simulating long-term space missions. Over 180 days, the sensor showed no drift and delivered data closely matching offline OD and biomass readings. This is crucial because if anything fails in space, you can’t just fix it. Our sensors offer reliability, robustness, and low-maintenance performance, even in such extreme scenarios.”
The company’s collaboration with Boehringer Ingelheim demonstrated how these sensors can help maintain turbidity below set thresholds during production processes to protect filtration systems from clogging and extend filter life.
Real-time viable cell density (VCD) monitoring was described as essential for modern perfusion strategies such as cell-specific perfusion rate (CSPR). Çelik stated: “In our study, Incyte Arc measured VCD every 30 minutes, enabling automated adjustment of media flow.” He added that this approach resulted in higher productivity and lower batch costs compared to traditional methods.
Hamilton offers both single-use and reusable sensors that deliver consistent results across different scales of operation—from small benchtop reactors to large-scale production bioreactors—which simplifies process scale-up.
Çelik emphasized the value of VCD monitoring for contract development and manufacturing organizations (CDMOs): “Monitoring VCD allows us to create a ‘fingerprint’ of the process, ensuring each batch follows the same growth profile. For CDMOs, this is especially valuable because it supports documentation and consistency for regulatory submissions.”
He also mentioned a partnership with EMGEN where they developed a viability model combining permittivity sensing with optical density measurements that achieved high accuracy.
According to Çelik: “First, it enables higher cell densities in the same bioreactor volume, which leads to greater product yields. Second, less media is consumed, and third, offline sampling is reduced, which cuts labor and assay costs.”
He stressed that inline sensors reduce contamination risks by providing non-invasive continuous monitoring: “Every offline sample carries risks of contamination and delay...inline sensors are non-invasive, sterile, and provide continuous real-time data that supports automation and better decision-making.”
On broader process control parameters he remarked: “pH, DO [dissolved oxygen], and metabolite levels are critical but only describe the environment. Cell density tells you how the cells are responding...VCD sensors help correlate environmental changes with cellular responses...”
Çelik concluded: “Cells are the engine of bioproduction. Monitoring them directly is essential.”
Hamilton Process Analytics has been expanding since developing its first pH sensors in 1989. The division now provides a range of analytical instruments focused on bioprocessing challenges—including specialized solutions for single-use systems—and supplies related accessories.
The company began operations in California in the late 1940s and now operates globally from headquarters in Nevada; Massachusetts; Switzerland; Romania; along with sales offices worldwide.
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