The road to market readiness: How Zeta drives innovation

Thomas Maischberger (links im Bild) ist neuer Corporate Head of Research and Development bei ZETA. / Thomas Maischberger (left) new Corporate Head of Research and Development at ZETA.

Gemeinsam mit einem Großkunden entwickelte ZETA wiederverwendbare, umweltfreundliche und stabile Konnektionslösung zu entwickeln - für den Transfer von Flüssigkeiten im Zuge der keimfreien Verarbeitung von Biopharmazeutika und Lebensmitteln. / Together with a major customer, ZETA developed a reusable, environmentally friendly and stable connectivity solution for the transfer of liquids in the aseptic processing of biopharmaceuticals and foodstuffs.

ZETA Mouseholes sind die intelligente Lösung zur Durchführung von Single-Use-Schläuchen durch Reinraumwände. Dabei ist gewährleistet, dass die unterschiedlichen Druckstufen der jeweiligen Reinraumklassen aufrecht erhalten bleiben. / Together with a major customer, ZETA developed a reusable, environmentally friendly and stable connectivity solution for the transfer of liquids in the aseptic processing of biopharmaceuticals and foodstuffs. / ZETA Mouseholes are the intelligent solution for routing single-use hoses through cleanroom walls. This ensures that the different pressure levels of the respective cleanroom classes are maintained.

Die Weiterentwicklung und Optimierung der Magnetrührwerkstechnologie wird im TechCenter ZETA vorangetrieben. / The further development and optimisation of magnetic agitator technology is being driven forward at the TechCenter ZETA.

ZETA’s declared mission "Accelerating the process of bringing drugs to market in order to save lives" already calls for innovative approaches. In fact, innovation is deeply rooted in the core of ZETA’s corporate culture. Driven by curiosity, enthusiasm, and a spirit of innovation, ZETA experts develop new products, solutions, and technologies for the pharmaceutical and biotech industries. A working environment where all employees have the opportunity to contribute their expertise is crucial.

Starting from the tangible benefit for the customer

Whether researching new technologies or developing innovative products, ZETA’s customer-centric approach is always about creating a specific benefit or added value for the customer. “We work in an applicationoriented way and usually start with very specific problems,” explains Thomas Maischberger, who was recently appointed Corporate Head of Research and Development. “We strive to push the boundaries of what biotechnological systems can achieve. Our aim is to translate the promise of new drugs into actual production facilities or systems, so that these therapeutics can reach the market and patients as early as possible.”

A key feature of ZETA is its integrated research approach, in which research and engineering go hand in hand within interdisciplinary teams. This involves working very closely with customers and regularly with universities and other research institutions.

Current highlights and research focus areas

ZETA’s innovation map ranges from data science, integrated engineering approaches and production simulation to issues relating to the sustainability of production sites. The list of innovative solutions and products is correspondingly long. An important focus of research is the characterization and optimization of bioreactors. Another major topic is magnetic agitator technology, which thanks to ZETA has made enormous progress in recent years. Innovative equipment components such as reusable sterile connectors for liquid transfer are also constantly being developed. ZETA is driving digitalization forward: Smart Engineering Services represent a software platform based on an integrated engineering toolchain. Integrated engineering combined with end-to-end digitalization of data results in the digital twin of the production system, enabling valuable smart tools, such as the Smart Maintenance Navigator app and paperless qualification as part of Integrated Digital Testing.

Best Practice Beispiele aus ZETA R&D

Product development: multi-use sterile connectors

True to the motto “Developing better solutions for the f uture t ogether”, Z ETA a nd a m ajor c ustomer based in Vienna succeeded in developing a reusable, environmentally friendly, stable connection solution for the transfer of liquids during aseptic processing of biopharmaceuticals and foodstuffs. Simple, quick, and safe to use, ZETA sterile connectors are particularly suitable for mobile containers. The connection process can be carried out in the general production area and does not require any additional technology to ensure the sterile integrity of the system, for example laminar flow. Stainless steel connectors and clamps are used to create a dry connection between two separate fluid pathways.

The system is suitable for all standard pipe and hose dimensions and has numerous advantages: The mechanical stability, pressure load tolerance and temperature resistance are high. The components can be cleaned and autoclaved and their reusability makes them particularly environmentally friendly. High process reliability is guaranteed for aseptic applications in all areas – from upstream and downstream to fill-and-finish.

A hands-on service: ZETA’s research bioreactor

In collaboration with the Styrian biotechnology company Bisy, ZETA operates a 50L bioreactor equipped with all relevant functions that is used for internal research and for the implementation of innovations on a process, simulation, automation and sensor level. The “ZETA Bire System” is ideal for collaboration projects with universities and industrial partners, as well as for external contract projects.

As an absolute all-rounder, the system can map a complete upstream process with living organisms. Bisy uses also for training purposes. The current focus is on the development of a new control algorithm for dissolved oxygen, which individually adjusts the oxygen saturation in the medium to the living culture via the optimum combination of agitator and gassing performance. Another area of focus is the implementation of the MTP concept on the Siemens SIMATIC PCS neo platform.

Forward-looking process automation: the MTP concept

Versatile, modular systems are the process industry's answer to constantly changing market requirements. Flexible technical solutions for the automation of modular plants are particularly high in demand – only with these can modular plant construction be implemented consistently.

The "Module Type Package" (MTP) concept gives the individual modules a digital description and enables them to be flexibly connected and orchestrated, in the sense of a plug & produce system. Production capacity can be increased by adding MTPready modules, and flexible reconfiguration allows for the production of different products. Standardization and modularization, both being driven forward by numerous companies and organizations, are already well advanced and the corresponding tools are available. The automation experts at ZETA are now working on a seamless integration of modules with process automation.

Process intensification: inline conditioning

Buffer solutions are essential media in the production of therapeutic proteins and other biomolecules. Increasing production titers, shorter batch times, capacity expansion of existing facilities and the intensification of bioprocesses have increased the volumetric demand for buffers and have led to operational bottlenecks. While many production facilities have improved their capacities through inline dilution of concentrates, the demand for buffers continues to rise. As a result, the supply with buffer solutions remains labor intensive and logistically challenging.

Proper planning and implementation of inline conditioning systems will alleviate production bottlenecks. Inline conditioning enables just-in-time preparation of buffers by mixing stock solutions. The advantages: the need for production space is minimized and flexibility in the use of buffer solutions is maximized.

ZETAs Innovation Labs

The TechCenter ZETA in Lebring provides an important research environment with space and infrastructure for various experiments and test series. However, it is by no means the only location where innovative concepts are developed. The topics of digitalization and data science are concentrated at the ZETA headquarters in Lieboch. In the field of automation, the Innovation Hubs conduct research at the ZETA site in Hallbergmoos and at SIGMA in Goldbach, Germany. ZETA in Vienna has a strong focus on process innovation, and the experts at Biotree in Bangalore are responsible for operator training. ZETA Innovation Labs sees itself as a hub for talents, bringing together entrepreneurs, researchers, investors, and experts.

There are currently 1400 employees working at 28 ZETA locations – an enormous potential of knowhow and creative ideas just waiting to be explored. In a research environment where all employees can contribute their respective expertise, the spirit of innovation is put into practice.

“In terms of R&D, we are currently working on adapting our structural organization, which will enable us to work together even more efficiently”, explains Thomas Maischberger, Corporate Head of Research and Development. “There will be a rather small permanent R&D team, which will be flexibly supplemented by experts from the various departments depending on research field, project, or questions to be explored. A suitable team will be put together for each research topic.”

The structure of the R&D department is intended to support ZETA's global approach to innovation, which aims to break new ground with foresight, and exchange t he k nowledge o f e mployees i n a m eaningful way.

A glimpse into the future

There are some industry trends that clearly indicate which topics will be in focus in the coming years. Thomas Maischberger and the ZETA team are working on products and services related to plant modularization, process intensification, integrated engineering, and the simulation of production processes.

In the long run, Maischberger expects that topics such as AI, digitalization, and platform-based process modeling will be the essential technologies that will step up productivity. Overarching questions related to climate change, resource scarcity, and incurable diseases will also be at the forefront of discussion. Looking to the future, the ZETA expert explains: “As an interdisciplinary team, we will be more challenged than ever to address complex issues as quickly as possible.”

No progress without innovation

Change and innovation are essential elements of ZETA’s corporate strategy. Managing Director Andreas Marchcler is convinced that “without continuous development, there is a risk of stagnation”. “Innovations are the key to success and tomorrow's earnings. At ZETA, we see innovation as a fundamental corporate value. We create spaces for inspiration, the generation of ideas, and the targeted implementation of innovations to ultimately create added value for our customers with our solutions. The ongoing inclusion of our industry partners ensures customer benefit and, therefore, success.”