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uPowerful, User-Friendly Controls The XDR is agitator includes a HDPE bottom mounted impeller and a
equipped with a fully integrated control console, unique sparge system consisting of microporous stainless
featuring intuitive process controls, steel disks and optional drilled holes that together impart
data historian, and robust automa- the system with tremendous flexibility crucial for todays cell
tion hardware/software. The system culture processes. Xcellerex also maintains multiple supply
sources to guard against supply chain disruptions.
enables precise process control,
and offers convenient real-time
Expert process support from Xcellerex With years
trending and other valuable data.
of experience running and supporting GMP biomanufactur-
When coupled with Xcellerexs
ing operations, Xcellerex designed the XDR system to deliver
process development experience
complete process control from the moment each system
and predictive modeling support,
starts up. No other single-use bioreactor is available with the
the XDR control platform assures optimized first-run XDRs depth of characterization, process support, and GMP-
process performance and reliability through tech readiness. Xcellerex is uniquely able to deliver critical control
transfer and scale-up. automation with instrumentation, functionality, process mod-
eling, tech transfer, and scalability.
uRobust Single-Use Components The XDR irradiated
single-use bag assembly consists of a USP Class VI LDPE
fluid contact layer, tubings for liquid additions and harvest,
sampling and probe ports, a disposable pressure sensor,
filtered gas lines, and high-functioning agitator system. The
u True plug-and-play performance: Connect gases and power and get u Each XDR Single Use Reactor System is shipped with a Turnover Package
started which includes XDR Operating Manual, System Specifications, FAT
commissioning report, system drawings, component operating manuals,
u Robust, self-installing magnetically-driven bottom-mount impeller: calibration records, and optional IQ/OQ protocols
No rotating seals, insertable shafts and connection hassles
u Xcellerex process experience and know how is built into every XDR
u Jacketed vessel ensures uniform temperature distribution throughout System: our process development expertise ensures that the process is
reactor up and running right the first time
u Flexible control systems automate temperature shifts, feeds, changes to u Xcellerex offers extensive XDR-specific predictive modeling and expert
sparge composition scale-up support
u Multiple probe configurations available, including pH, DO, CO2, and u Enhanced sparge control and CO2 stripping capabilities not offered on
biomass other single use systems
u Accurate gas control using mass flow controllers on all systems (optional u Designed and fully characterized to deliver scalable cGMP processes from
MFC for headspace on XDR50) 10L to 2000L
u Bag material sourced from multiple manufacturers for supply chain security u Xcellerex has years of cGMP manufacturing experience operating the XDR
system. GMP product made in the XDR is currently being used in clinical
u Single-use design eliminates time consuming CIP, SIP and cleaning valida- trials and commercial XDR facilities are currently being prepared for com-
tions procedures missioning.
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All specifications are subject to change without notice.
SYSTEM SPECIFICATIONS
XDR-50 XDR-200 XDR-500 XDR-1000 XDR-2000
BIOREACTOR
Tank ID (in) 12 22 30 38 48
Vessel Material of Construction Jacketed 304 SS Jacketed 304 SS Jacketed 304 SS Jacketed 304 SS Jacketed 304 SS
Impeller Bottom mounted, magnetically-driven, single-use impeller integrated with bag assembly
Impeller location Center 90 15 off center 15 off center 15 off center 15 off center
Standard Stanless steel sintered disks Stanless steel sintered disks Stanless steel sintered disks Stanless steel sintered disks Stanless steel sintered disks
Sparger Drilled Hole Drilled Hole Drilled Hole Drilled Hole Drilled Hole
Optional
CO2 stripping CO2 stripping CO2 stripping CO2 stripping CO2 stripping
PROCESS INSTRUMENTATION
pH probes 1 2 2 2 2
DO probes 1 2 2 2 2
Standard 4 4 4 4 4
MFCs (Brooks)
Additional (optional) 2 2 2 2 2
Optional: 3 kw heater/
Optional: 9 kw heater/ 1.5 hp chiller combo
0.5 ton chiller combo
Load Cells 3 4 4 4 4
Utility Requirements Process gases / 110V, single phase, 60 hz / TCU: 230V, 3 phase, 60 hz (EU: 380V, 3 phase, 50 hz)
E-Stop Integrated Safety Circuit for pumps, agitator, TCU, and filter heater
NOTE: This document describes standard systems and commonly requested options. Additional custom-engineered systems are also available to meet unique application needs. Ask your Xcellerex representative for details.
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PERFORMANCE CONTROL SPECIFICATIONS All specifications are subject to change without notice.
Accuracy 0.1 C
NOTE: For high-density microbial applications, please ask about the XDR-50 Turbo system.
System Dimensions
XDR-50 XDR-200 XDR-500 XDR-1000 XDR-2000
28 in 37 in 48 in 52 in 61 in
Depth (Vessel & Instrumentation)
(71 cm) (94 cm) (122 cm) (132 cm) (155 cm)
HMI Control Unit Dimensions: 23.375 in x 30.75 in x 56.75 in (60 cm x 78 cm x 144 cm)
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CONTROL AUTOMATION PLATFORM
The XDR Control Platform is comprised of a Rockwell/Allen Bradley controller with Wonderware HMI
and data historian. The platform delivers precise process control and offers a level of flexibility and
convenience that is unmatched in the industry.
In addition to robust control architecture, the XDR features a highly intuitive user interface that speeds
operator training and efficiency.
The XDR system enables rapid understanding and interpretation of active control strategies through
the use of graphical symbols. (See Screen 2)
In addition, set-point automation tables enable the easy automation of set-point changes, permitting
live adjustments to ramp or step to new value. (See Screen 3)
uPowerful Control Strategies for Fast Response, Tight Control Screen 2 - Cascade Loop Control
Cascade control strategies of pH, DO, and volume result in very tight control of critical process
conditions.
Flexible closed loop control of critical process parameters support improved yields:
Agitation Sparge
Gas mixing Gas overlay
Liquid addition and removal Temperature
pH DO (See Screen 4)
Weight
Export of data to other master data repository systems is supported with built-in functionality
Real time alarming protects process integrity and helps avoid lost batches
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XDR PERFORMANCE DATA CHO Process -Titer Data
Figure 1: CHO Process - Titer Data (XDR
XDRvs.vs10L
10LGlass
glassReactor)
reactor
Figures 1-3 illustrate examples of first-run data
for a series of CHO processes, demonstrating the 120
on request. XDR-200
80 10L glass
Titer (ug/mL)
10L glass
60
40
20
14
100
12
XDR-1000
10 XDR-200
XDR-200
8 60
10L glass
10L glass
6
40
20
2
FIGURE 2: XDR achieved equivalent or better cell
viability during scale-up from a 10 liter glass reac- 0 0
0 2 4 6 8 10
tor to a 200L XDR to a 1000 liter XDR. Day
100
14
90
12 80
Viable Cell Density (e6 cells/mL)
XDR-1000 70
Percent Viable Cells
10
10L glass 60
8
XDR-200 50
6 40
30
4
20
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FOR ADDITIONAL INFORMATION
To learn more about XDR Single-Use Bioreactors or other Xcellerex systems or services,
please contact customer service at:
Telephone: 1-508-480-9235
Email: sales@xcellerex.com