Successful fermentation depends on understanding what is happening inside the bioreactor in real time. Continuous off-gas analysis provides direct insight into microbial metabolism, cell growth, oxygen utilization, and carbon dioxide production, allowing operators to optimize fermentation conditions and maximize product yield.
Process Insights delivers advanced bioprocess gas analyzers for fermentation monitoring, cell culture monitoring, and bioreactor off-gas analysis. Our fixed magnetic sector and quadrupole mass spectrometers continuously measure multiple gases while automatically calculating Oxygen Uptake Rate (OUR), Carbon Dioxide Evolution Rate (CER), and Respiratory Quotient (RQ) for complete bioprocess visibility.
Why Off-Gas Analysis is Critical
Continuous off-gas monitoring gives operators immediate feedback on culture health and fermentation performance.
Benefits include:
- Optimize microbial growth
- Improve mammalian cell culture performance
- Increase fermentation yields
- Detect contamination earlier
- Improve nutrient feed strategies
- Reduce batch failures
- Accelerate process development
- Improve scale-up success
- Support automated process control
- Eliminate delayed laboratory analysis
Off-Gas Analysis for Fermentation Monitoring and Cell Culture Monitoring
Off-gas analysis is one of the most powerful tools available for understanding biological activity inside fermenters and bioreactors. By continuously measuring oxygen consumption and carbon dioxide production, manufacturers gain real-time visibility into metabolic activity, culture health, and process performance.
Process Insights solutions support:
- Fermentation off-gas analysis
- Bioreactor off-gas monitoring
- Cell culture process monitoring
- Continuous gas monitoring
- Gas composition analysis
- Online process analytics
- Real-time bioprocess control
Continuous monitoring reduces reliance on manual sampling while providing faster, more accurate process insights that improve operational efficiency and product consistency. Real-time off-gas monitoring is widely used to characterize fermentation and cell culture processes while supporting process optimization and yield improvement.
Why Choose Process Insights?
MGA 1200CS™
Ideal for:
- Up to 99–100 bioreactors
- Simultaneous analysis of up to 16 gases
- New analytical data approximately every 3 seconds
- Low-flow sampling for small bioreactors
- Automatic OUR, CER, and RQ calculations
- CyberSecure Industry 4.0 architecture
MAX300-BIO™
Perfect for:
- Laboratory research
- Process development
- Pilot-scale fermentation
- Production fermenters
Benefits include:
- Quadrupole mass spectrometry
- Real-time multi-gas monitoring
- Flexible sample multiplexing
- Continuous off-gas analysis
- Fast analytical response
What Can Be Measured?
Unlike conventional CO₂/O₂ analyzers, Process Insights systems simultaneously measure multiple gases from a single analyzer.
Typical gases include
- Oxygen (O₂)
- Carbon Dioxide (CO₂)
- Nitrogen (N₂)
- Argon
- Hydrogen
- Methane
- Water Vapor
- Additional process gases
Derived calculations include:
- Oxygen Uptake Rate (OUR)
- Carbon Dioxide Evolution Rate (CER)
- Respiratory Quotient (RQ)
- Gas utilization efficiency
- Metabolic activity trends
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Why Choose the MGA 1200CS for Fermentation Control?
The MGA 1200CS is a high-performance gas analysis solution for fermentation control, delivering fast, accurate measurements of CO₂ and O₂ in real time. With advanced infrared and paramagnetic sensors, it enables precise control of fermentation conditions to boost yield, consistency, and efficiency.
Engineered for easy integration into industrial and lab-scale fermentation systems, the MGA 1200CS features a robust, low-maintenance design ideal for demanding environments.
Powered by a CyberSecure-enabled fixed magnetic sector mass spectrometer, it supports up to 16 gas components across multiple streams—with best-in-class stability, minimal drift, and extended calibration intervals. One analyzer, maximum performance.
MAX300-BIO™ – EXTREL™ Bioreactor & Fermentation Quadrupole Mass Spectrometer
One MAX300-BIO Bioreactor & Fermentation Quadrupole Mass Spectrometer is capable of analyzing up to 80 samples with the use of a single FAST multi-port valve. The MAX300-BIO is a powerful analytical instrument designed for monitoring the gases produced and consumed during biological fermentation processes. Here are some of the benefits:
- Accurate and Reliable: Provides accurate and reliable measurements of gas concentrations, ensuring the optimization of bioreactor performance.
- Real-Time Monitoring: Provides real-time monitoring of gas concentrations, allowing for quick adjustments to bioreactor conditions.
- Easy to Use: Easy to use, with an intuitive interface and simple calibration procedure.
- Low Maintenance: Requires minimal maintenance, reducing downtime and maintenance costs.
- Multiple Gas Detection: Capable of detecting multiple gases simultaneously, including CO2, O2, H2, and CH4, making it a versatile option for bioreactor monitoring.
- Comprehensive Data Analysis: Includes data analysis software, allowing for comprehensive data analysis and visualization.
- Enhanced Bioreactor Performance: Enables the optimization of bioreactor performance, leading to increased yields and improved product quality.
