Eilersen Electric Digital Systems A/S (Denmark) - How Repligen ensures stable bioprocessing with Eilersen digital capacitive load cells

From fermentation to purification, Eilersen’s digital capacitive load cells provide Repligen with accurate, reliable measurements that enable fewer deviations, more consistent batches, less downtime and easier validation.

Repligen: Enabling Global Bioprocessing with Digital Accuracy:

Repligen is a global bioprocessing-focused life sciences company known for their high-quality products and innovative technologies.

Originally founded as a fermentation lab, the facility in Sweden has evolved through decades of ownership changes, technology upgrades, and growing demands for pharmaceutical-grade production. 

The site has two manufacturing lines. The first line produces affinity ligands. The second produces cell culture supplements for mammalian cell fermentation.

Both lines are part of a tightly controlled production process where accuracy and control at every stage is crucial. Even small deviations in weight or flow can affect quality and yield. 

To avoid deviations and ensure complete process control, Repligen relies on Eilersen’s digital capacitive load cells for critical processes in the harvest and purification steps. 

The Challenge: Maintaining Stability in Dynamic Bioprocess Environments:

By the mid 2000s, the facility faced a familiar challenge in fermentation and recovery systems: fluctuating and inconsistent level measurements. Manual measurement systems and radar lacked accuracy at low volumes, while newer systems struggled with vibrations and disturbances caused by agitators and pumps. 

“Many of our processes requires very exact measurements to supply the right flow. Other measurement methods were simply not adequate or did not perform due to the vibrations and disturbances”, says Martin Erlandsson, Validation and Automation Sr. Specialist at Repligen. 

The limitations became critical as Repligen shifted toward more automation and tightly controlled processes. The need for accurate, stable and reliable weighing was clear, not just for production consistency, but also for traceability and GMP compliance. 

The Solution: Digital Capacitive Load Cells for Accuracy and Reliability:

After the first load cells being installed in 2006, the digital capacitive technology quickly distinguished itself. Installation was simple, and integration directly via Profibus to the SCADA software was easy and enabled accurate automation of flow, dosing and transfers between tanks. 

Because capacitive load cells remain stable under vibrations, sideloads, and mechanical disturbances, Repligen experiences fewer measurement deviations during the critical fermentation, harvest and purification steps. 

“Since the first Eilersen installation in 2006, every single load cell has performed excellently. Our calibration method has a higher measuring uncertainty that what we can detect by calibration on our load cells. So you have definitely delivered on the promise of a stable and reliable load cell” says Martin.

With a simple, hygienic mechanical installation that is easy to clean, the Eilersen capacitive load cells are ideal for environments that require rigorous routine cleanings.

Eilersen’s advanced digital signal processing ensures that the load cells deliver stable, reliable measurements in environments affected by vibrations, rapid flow changes, or mechanical agitation.

Through the proprietary digital filters, the system isolates the true weight signal without slowing down response time, ensuring accurate control during critical feeding, harvest and purification steps. This gives Repligen tighter control loops, more confident automation decisions, and highly stable data that supports GMP documentation and batch release.

The Results: Long-Term Stability, Sustainability, and Reduced Maintenance:

Since installing Eilersen load cells nearly two decades ago, Repligen has seen consistent accuracy, reduced maintenance, and significant time savings across its Swedish production site. 

Because the system maintains stable readings over years of operation, calibration intervals have been extended, reducing water consumption and time spent for verification procedures. 

“Each calibration can use several thousand litres of water,” Martin explains. “Now we can calibrate far less frequently because the load cells simply don’t drift. It’s better for the process, better for the environment, and better for productivity”.

Repligen’s operators also benefit from the simplicity of the setup. With no need for manual recalibration after load cell cable replacements or equipment maintenance, service time is significantly reduced. 

This is possible due to capacitive technology not being dependent on the cable length. This independency also allows for custom cable lengths, ensuring less surface area to clean in controlled environments.

“They’re robust, hygienic, and maintenance -free” says Dan Kabrell, Electrician at Repligen Sweden, “it’s the kind of equipment you install and don’t have to think about again”.

Built for the Future of Automated Bioprocessing:

As Repligen have continued to expand its production capabilities, Eilersen load cells have been a part of every new installation. The system’s accuracy and digital foundation make it ready for the next generation of automation and data-driven bioprocess control. 

“Eilersen has been part of our process setup for nearly 20 years”, Martin concludes, “The capacitive technology supports the reliability we need, and that reliability gives us the confidence to automate more.” 

With its digital weighing platform and reliable accuracy, Eilersen’s capacitive technology support the next generation of automated, data-driven bioprocessing, helping Repligen scale efficiently while maintaining compliance and quality.

Which Eilersen load cells are used at Repligen?

• Compression load cells under feed vessels to fermenters
• Compression load cells under recovery vessels / harvest vessels
• Compression load cells under harvest vessel feeding a centrifuge
• Compression load cells under fluid transfer vessels 
• Beam load cells under mobile purification vessel
• Bench scales on tables next to vessels to measure how much of various additions are used by the fermentation

Quick facts about Eilersen’s Digital Capacitive Load Cells:

• Up to 1000% overloads and sideloads 
• Hygienic design and installation
• Up to 99.99% accuracy 
• Wide selection of interface integrations
• Integrated digital diagnostics of individual load cells
• Used for process weighing in biopharma and food applications for more than 50 years