about 1 week. If, instead of the simulations on the Digital Twin, real cultivations had
to be carried out during the control strategy development process, the development
time would have been extended to up to 2 months. Besides the significant time
savings, the consumption of resources was also significantly reduced due to the
smaller number of real cultivations.
4.2.4 Case Study Discussion
This case study demonstrated the enormous potential of the Digital Twin “SSF-BCSimulator” to support the control strategy development and optimisation for the
cultivation of S. cerevisiae. By utilising the Digital Twin, it was possible to effectively develop both control that uses online values (RQ feedback control) and control
that uses offline values (OLFO control). By conducting simulations using the Digital
Twin, real experiments could be avoided that would have been associated with the
consumption of resources and time. By using the Digital Twin, an estimated amount
of resources of about 60% and time of about 50% could be saved in the development
process of both control strategies compared to conventional control strategy
development.
In this case study, we were able to demonstrate the beneficial utilisation of Digital
Twins for the development, optimisation and realisation of bioprocess control
strategies. An important prerequisite for the Digital Twin utilisation for control
development is the validation of a high accuracy in mapping the bioprocess
dynamics.
The presented Digital Twin “SSF-BC-Simulator” is also capable of mapping the
enzymatic process of starch hydrolysis as well as the biocatalysis of ethyl (S)-3hydroxybutyrate. For these processes various control strategies will be developed in
future, supported by the Digital Twin.
5 Conclusion and Future Perspectives
This chapter demonstrated the enormous potential of Digital Twins or “early-stage”
Digital Twins as a control strategy development tool and their application to
bioprocesses. The use of Digital Twins enables the development of advanced
controllers that increase the efficiency of bioprocesses. By accelerated and parallel
running simulations on the Digital Twin, the development time is drastically reduced
compared to conventional control strategy development. In the past, production
usually had to be interrupted to investigate the dynamic behaviour of the
bioprocessing plant under consideration, as well as the dynamics of different controlled systems, which is necessary for the development of control strategies. By
using Digital Twins, the production plants can remain in operation during controller
development and optimisation. The presented case study demonstrates a rapid and
effective controller transfer to the real plant as soon as the new controllers have been
Digital Twins for Bioprocess Control Strategy Development and Realisation
89
to be carried out during the control strategy development process, the development
time would have been extended to up to 2 months. Besides the significant time
savings, the consumption of resources was also significantly reduced due to the
smaller number of real cultivations.
4.2.4 Case Study Discussion
This case study demonstrated the enormous potential of the Digital Twin “SSF-BCSimulator” to support the control strategy development and optimisation for the
cultivation of S. cerevisiae. By utilising the Digital Twin, it was possible to effectively develop both control that uses online values (RQ feedback control) and control
that uses offline values (OLFO control). By conducting simulations using the Digital
Twin, real experiments could be avoided that would have been associated with the
consumption of resources and time. By using the Digital Twin, an estimated amount
of resources of about 60% and time of about 50% could be saved in the development
process of both control strategies compared to conventional control strategy
development.
In this case study, we were able to demonstrate the beneficial utilisation of Digital
Twins for the development, optimisation and realisation of bioprocess control
strategies. An important prerequisite for the Digital Twin utilisation for control
development is the validation of a high accuracy in mapping the bioprocess
dynamics.
The presented Digital Twin “SSF-BC-Simulator” is also capable of mapping the
enzymatic process of starch hydrolysis as well as the biocatalysis of ethyl (S)-3hydroxybutyrate. For these processes various control strategies will be developed in
future, supported by the Digital Twin.
5 Conclusion and Future Perspectives
This chapter demonstrated the enormous potential of Digital Twins or “early-stage”
Digital Twins as a control strategy development tool and their application to
bioprocesses. The use of Digital Twins enables the development of advanced
controllers that increase the efficiency of bioprocesses. By accelerated and parallel
running simulations on the Digital Twin, the development time is drastically reduced
compared to conventional control strategy development. In the past, production
usually had to be interrupted to investigate the dynamic behaviour of the
bioprocessing plant under consideration, as well as the dynamics of different controlled systems, which is necessary for the development of control strategies. By
using Digital Twins, the production plants can remain in operation during controller
development and optimisation. The presented case study demonstrates a rapid and
effective controller transfer to the real plant as soon as the new controllers have been
Digital Twins for Bioprocess Control Strategy Development and Realisation
89