The superpro simplifies the model using "Pseudo-Continuous" blocks. They replace the dynamic bioreactor with a series of CSTRs (Continuous Stirred-Tank Reactors) and use the Rate-Based kinetics tab.
The simulation reveals that the continuous capture step (three columns in series) fails if the upstream perfusion rate dips by just 8%. They add a surge tank that the average user would have forgotten. The model saves $2M in failed pilot runs. 5. The Environmental "What If" (Water & Solvent Recycle) The Challenge: A plant is hitting its effluent limit for organic solvents. Purchasing a distillation column is expensive. superpro designer examples
The superpro uses Cycle Timing Analysis on the depth filters and AEX columns. They discover that a single column is idle 65% of the time waiting for the bioreactor harvest. They add a surge tank that the average
The difference between a casual user and a (an expert who makes the software sing) lies in handling complexity: multiple campaigns, equipment turnover, environmental impact, and cost analysis. The Environmental "What If" (Water & Solvent Recycle)
An expert user sets up "Campaign Mode" with staggered scheduling. Instead of modeling one batch, they chain 50 batches of Product A, followed by a cleaning cycle, then 30 of Product B.
Using the Solvent Recovery & Recycling library, the expert hooks the waste stream to a simulated distillation column. They then close the loop by sending the recovered solvent back to the extraction step.
They use the Equipment Turnaround Time and Shared Storage features to prevent cross-contamination while maximizing annual output. The result? A 22% increase in utilization without buying new tanks. 2. Viral Vector (AAV) Bottleneck Busting The Challenge: Gene therapy production has notoriously low yields. A startup’s downstream purification (chromatography + TFF) is the bottleneck.