IOT project

The Ultrafiltration/Diafiltration (UF/DF) process is a critical step in downstream biopharmaceutical purification, used to concentrate and buffer-exchange monoclonal antibodies prior to formulation. Traditionally, the operation is manually controlled — operators adjust the Watson-Marlow peristaltic pump speed to maintain the transmembrane pressure (TMP) within the target range. This manual regulation leads to frequent TMP fluctuations (±0.3 bar), inconsistent flow rates, and significant operator workload. Such variability can impact product recovery, increase process cycle time, and pose challenges in achieving consistent performance across batches.

This project aims to optimize and simplify the UF/DF process by implementing a low-cost automation and monitoring system using Node-RED with a PID (Proportional-Integral-Derivative) controller. Real-time data from pressure, pH, and conductivity sensors will be captured using an Arduino interface and communicated to a Watson-Marlow 520 pump via RS-485 (Modbus RTU). The system will continuously adjust pump speed to maintain stable TMP automatically.

A baseline study will be conducted to collect TMP fluctuation data and manual intervention frequency. After automation, performance will be evaluated for TMP stability, operator involvement, and total filtration time. The project will also apply Project Management tools such as Gantt charts, CPM, and risk assessment to plan and monitor implementation phases.

Expected outcomes include a 60% reduction in manual interventions, TMP variation reduced to within ±0.05 bar, and a 10–12% reduction in total UF/DF cycle time. This approach enhances process robustness, operator efficiency, and data integrity while reducing operational complexity