ExPro R Series
(PAT Raman Analyzer)

ExPro R Series eliminates manual sampling and enables real-time monitoring of critical metabolites (lactate, glucose, VCC) in cell culture bioreactors.
By providing instant feedback on metabolic status, it transforms bioreactor operation from reactive batch control to proactive fed-batch optimization, directly improving cell viability, productivity, and process consistency.

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Overview – ExPro R Series

Why Buy ExPro R Series?

You’re spending 2-6 hours waiting for sampling results while your cells struggle without nutrients. Batches are inconsistent, and you’re paying $80k/year for analysis that comes too late to help.

ExPro R Series monitors glucose, lactate, and cell count in real-time, automatically adjusting feeding before problems start. Batch variance drops from ±30% to ±5%, batches finish 2 days faster (giving you 3 extra batches/year), and analysis costs fall from $500 to $200 per batch.

Initial investment of $100-140k pays back in 2-3 years through labor savings, reduced costs, and extra revenue. It’s the difference between reactive troubleshooting and proactive control.

Why Choose ExPro-R4

The Solution: ExPro-R4 Real-Time Monitoring

The sensor continuously:

  • Collects spectra in real-time (second-level intervals)
  • Automatically predicts Lactate, Glucose, VCC (via WaveCraft models)
  • Automatically integrates with reactor control system via OPC UA
  • Executes fed-batch algorithm based on real-time feedback

Results:

  • Real-time feedback → immediate process control
  • Automation → 90% labor reduction
  • Sampling elimination → no contamination or cell damage
  • High accuracy → consistent batch performance
  • Data-driven decision making → process optimization

The Problem: Manual Sampling in Bioreactors

Operators manually extract samples every few hours:

  • Manual sample extraction from reactor (time-consuming, contamination risk)
  • Transport to laboratory (additional time delay)
  • Analysis execution (2-6 hours required)
  • Results interpretation and process adjustment (often too late)

Results:

  • Real-time feedback impossible → process control unfeasible
  • High labor dependency → increased costs
  • Sampling contamination risk → data unreliability
  • Sampling itself damages cells
  • Batch-to-batch variability increases (subjective manual judgment)

Key Benefits

Superior Signal Stability & Data Quality
Enhanced low-noise detection and automatic calibration achieve highly reproducible measurement. Consistent spectra from identical samples establish a reliable foundation for quantitative analysis.

Multi-Point Process Monitoring with Single Base Unit
Up to 4 channels simultaneously enable monitoring multiple reaction vessels and various process stages on one platform. Maximize process control efficiency.

Complete End-to-End Analytics Platform
From data acquisition (WaveFlow) → preprocessing → model building → real-time prediction (WaveCraft)—all integrated without external software. Lower user barriers accelerate analytical decision-making.

Compact, Modular, Future-Ready Design
<12kg footprint easily deploys in space-constrained process environments; modular optics simplify upgrades and maintenance. Maximize initial investment value with long-term flexibility.

Seamless Process Integration via OPC UA
Industry-standard OPC UA protocol enables direct connectivity with existing MES/SCADA/PLC systems. Eliminate manual data entry for real-time closed-loop process control.

Key Advantages Over Manual Sampling

Real-Time Decision Making

ExPro R Series:

  • Provides analysis results within 5 minutes
  • Real-time monitoring of lactate and glucose trends
  • Automatically executes glucose feed before depletion
  • Detects lactate accumulation early → adjusts agitation/oxygen

Manual Sampling:

  • 2-6 hour delay until analysis results arrive
  • Process state already changes by decision time
  • Misses optimal process adjustment timing

Automated Fed-Batch Control

ExPro R Series:

  • Automatically executes pre-defined algorithm
  • Glucose < 2 g/L → automatic feeding
  • Lactate > 10 g/L → automatic oxygen increase
  • Consistent results → reduced batch-to-batch variation

Manual Sampling:

  • Relies on operator experience and intuition
  • Different decisions for each batch
  • Difficult to find optimal point

Elimination of Sampling Risk

ExPro R Series:

  • No external intervention (non-invasive)
  • No cell damage
  • Sampling contamination eliminated
  • 100% measurement reliability

Manual Sampling:

  • Opening reactor each time → contamination possibility
  • Shear stress on cells → cell damage
  • Sampling extraction variability → measurement unreliability

Improved Process Understanding (PAT)

ExPro R Series:

  • Continuous real-time data → full dynamics understanding
  • Clear metabolic patterns in cell culture
  • Early stress signal detection
  • Meets FDA PAT/QbD requirements

Manual Sampling:

  • Only sporadic data from a few time points
  • Unable to understand full dynamics
  • Process variation factors unclear

Technical Integration

Hardware: Compact Probe in Bioreactor

ExPro-R4 probe:

  • 316L stainless steel → Sterilizable, corrosion-resistant
  • Helical port installation → Installed on reactor wall helical port
  • Non-invasive optics → No cell damage
  • Fiber-optic design → Connects to external analyzer
  • Multiple channels → Monitor up to 4 bioreactors simultaneously

Software: Real-Time Metabolite Prediction

Model 1: Viable Cell Concentration (VCC)

  • Input: Raman spectrum (100-3600 cm⁻¹)
  • Output: cells/mL (immediate)
  • Accuracy: ±5-10%
  • Signal source: Protein, RNA, lysosome, and other cellular components

Model 2: Glucose Concentration

  • Input: Raman spectrum
  • Output: g/L (immediate)
  • Accuracy: ±0.5 g/L
  • Signal source: C-O and C-C stretching (1000-1200 cm⁻¹)

Model 3: Lactate Concentration

  • Input: Raman spectrum
  • Output: g/L (immediate)
  • Accuracy: ±1 g/L
  • Signal source: C-O and C-H stretching (1300-1450 cm⁻¹)

Model 4: Glutamine/Glutamate (Optional)

  • Input: Raman spectrum
  • Output: mM (immediate)
  • Signal source: Amide I, II (1600-1700 cm⁻¹)

Integration: OPC UA to Bioreactor Control System

What is OPC UA?
OPC UA (Open Platform Communications Unified Architecture) is an international standard communication language that allows industrial machines to talk to each other automatically.

Why does it matter?
Without OPC UA, ExPro-R4 can measure glucose and tell you “glucose is 1.5 g/L”—but your bioreactor’s control system won’t understand it. You’d have to manually read the result and push the button to add glucose. With OPC UA, ExPro-R4 and your bioreactor speak the same language, so glucose measurements trigger automatic feeding without any human intervention.

Compatibility:
Most modern bioreactors support OPC UA, so ExPro-R4 integrates seamlessly with your existing system.

ExPro-R4 Probe (in Bioreactor)
 ↓ (Raman spectra, real-time) 
WaveFlow (Data Acquisition)
 ↓ (Automatic prediction) 
WaveCraft (4 Metabolite Models)
 ↓ (VCC, Glucose, Lactate, Glutamine) 
OPC UA Server (ExPro-R4)
 ↓ (OPC UA Protocol) 
Bioreactor Control System (MES/SCADA)
 ↓ (Fed-batch algorithm) 
Bioreactor Actuators
 → Glucose feed pump (automatic)
 → Oxygen supply (automatic)
 → pH control (automatic)
 → Temperature (manual or auto)

FAQ: For Bioreactor User

A: Yes. If the bioreactor has a helical port, installation is possible. Most modern bioreactors (Thermo, Mettler, Sartorius, ATMI) are compatible.

A: No. The probe is non-invasive; using only light signals, it causes no harm to cells.

A: With 20-30 standard samples, a stable model can be built within 2-3 weeks.

A: Yes. It supports OPC UA protocol, compatible with most modern SCADA/MES. Legacy systems may require custom integration.

A: Glucose ±0.5 g/L, Lactate ±1 g/L, VCC ±5-10%—sufficient for practical operations.

A: Probes are replaced every 2-3 years; basic maintenance costs ~$10-15k annually.

Specifications

Common Specifications

Usage

Real-time process monitoring · Reaction tracking · Quality control

Wavelength for Laser

785 nm (532 nm optional)

Spectral Range

100 – 3,600 cm⁻¹

Spectral Resolution

6 cm⁻¹

Detection Type

High-sensitivity TE-cooled CCD / Low-noise signal processing

Cooling Type

2-Stage TEC Active Cooling (–60 °C)

Optical Configuration

Holographic grating + fiber-coupled module

Number of Channels

Supports simultaneous analysis of up to 4 channels

Software

WaveFlow (data acquisition & control) + WaveCraft (modeling & analysis)

Communication Interface

OPC UA

Power Requirements

AC 100 – 240 V / 50 – 60 Hz / < 100 W

Dimensions / Weight

430 (W) × 360 (D) × 160 (H) mm / < 12 kg

Key Features

High-sensitivity, low-noise detection; automatic baseline correction;
real-time modeling; compact industrial design; multi-channel process analysis support

Probe Tube Material

316L stainless steel

Probe Length

220 mm (120 ~ 320 mm customizable)

Outer Diameter

785 nm (532 nm, optional)

Fiber Optic Cable

100 – 3,600 cm⁻¹

Connector

Excitation (FC, 100 um, NA 0.22)
Collection (SMA, 200 um, NA 0.22)

Support

Downloads

  • MRX N1 Leaflet_en_v1.0
    The MRX N1 is a High-Throughput Near-Infrared (HT-NIR) Analyzer designed for rapid and large-scale sample analysis. With 96-well plate compatibility and advanced chemometric modeling, it…
    download
  • MRX N1_Leaflet_kr_v1.0
    MRX N1은 신속하고 대규모 시료 분석을 위해 설계된 고처리량 근적외선(HT-NIR) 분석기입니다. 96웰 플레이트와의 호환성과 첨단 화학 계량 모델링을 통해 빠르고 정확하며 비파괴적인 정량 분석이 가능합니다.
    download

Applications

  • MRX_Rapid BCA Protein Quantification Analysis using the MRX A2000
    In this experiment, Rapid BCA protein quantification analysis was performed using the automated [Workflow] function of the K LAB MRX…
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    PDF

  • MRX_Rapid BCA 단백질 정량 분석
    본 실험에서는 K LAB MRX A2000 Microplate Reader의 자동화된 [Workflow] 기능을 이용하여 Rapid BCA 단백질 정량 분석을 수행하였다. 0.125–5.000 mg/mL…
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  • MRX_Endotoxin 모드를 활용한 Kinetic Turbidimetric 내독소 예비시험
    본 시험은 『대한민국약전』 별표 5 일반시험법 중 박테리아 내독소 시험(Bacteria Endotoxin Test, BET)에 따라, 광학적 분석법 중 하나인 비탁법(Turbidimetric Method)을…
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  • MRX_Procedure for Protein Quantification using the Bradford Assay
    This technical note provides a detailed procedure for protein quantification analysis using the MRXA2000 microplate reader and the Bradford Assay….
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  • MRX_Bradford Assay를 활용한 단백질 정량 분석
    본 테크니컬 노트에서는 마이크로플레이트 리더인 MRXA2000을 활용하여 Bradford Assay를 이용한 단백질 정량 분석의 체계적인 절차를 상세히 안내하고 있습니다. MRX A2000은…
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Troubleshooting

  • How to separate Top cover for New POP series
    How to separate Top cover for New POP series How to separate Top cover for New POP series#TS-PR1151-001 Introduction Procedure
    Read More
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