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Fundusze Europejskie · Rzeczpospolita Polska · Dofinansowane przez Unię Europejską

EU Project

Implementing a project co-financed by EU Funds

MODICA P.S.A. is carrying out an R&D project co-financed by the European Union under the FENG (Fundusze Europejskie dla Nowoczesnej Gospodarki / European Funds for a Modern Economy) programme.

Results of the project

Adaptive capabilities developed in the EU project

We are developing the adaptive capabilities of ADT in three phases. Phases 1 and 2 are achieved; phase 3 is under way, and pilot partners get its capabilities first.

What the project will deliver

A digital twin that adapts to the lab, instead of the lab adapting to it: it recognises its hardware, keeps a batch going when equipment fails, and explains what is wrong and what to do.

  • Automatic detection of the bioreactor’s hardware configuration
  • An alternative configuration when a component fails, so the batch can continue
  • Diagnosis of process and equipment faults, with fixes checked by simulation
  • Sensitivity analysis: which configuration parameters matter most for the bioprocess
  • Live monitoring, with the model’s confidence shown to the operator
  • An audit trail of every algorithmic decision and operator action
  • Configuration that follows changes in the lab without a restart
Phase 1 R&D phase achieved Hardware awareness & adaptivity The twin knows which hardware it mirrors. When a sensor or module fails, it finds an alternative configuration — the same model on another module, compatible capabilities, or a soft sensor — or states clearly that there is none. Tested on a QB bioreactor
19 / 21
fault scenarios detected (target > 70%)
0–3 s
to detect a lost connection
48 h+
connection, gaps under 15 min
≥ 95%
process-parameter sync
Phase 2 R&D phase achieved Expert system The twin diagnoses problems in the process or the equipment and suggests solutions, checked by simulation in the twin before they reach the operator. Project KPIs
≥ 75%
correct diagnoses
≥ 75%
cases with at least one effective suggested fix
Phase 3 R&D phase in progress Dynamics & autonomy The twin keeps up with a changing lab: new devices and signals are discovered, and configuration updates without restarting the system. Project targets
≤ 3 min
to sync a configuration change (≥ 90% of cases)
≤ 0.5 h
to detect and remove a bioreactor fault

Project title

Carrying out R&D works to develop an innovative, adaptive Digital Twin (Adaptive Digital Twin — ADT) for the modelling of biotechnological processes, leveraging modular bioreactor hardware components, enabling efficient bioprocess scaling and near-continuous operation.

Project objective

To develop a product innovation: an adaptive Digital Twin for the simulation, monitoring and optimisation of biotechnological processes. The system will work with modular bioreactor components, enabling dynamic configuration and scaling of bioprocesses.

Expected results of the R&D module

  • A complete bioprocess-modelling solution integrating hardware with a digital system.
  • Dynamic bioreactor configuration — automatic detection, synchronisation and control of modules.
  • Bioprocess optimisation through algorithms that exploit the properties of modular systems.
  • Improved efficiency and sustainability — higher component reusability, better equipment utilisation.

Implementation outcome

MODICA will deploy the developed technology in its own operations, and ultimately Modica's customers will benefit from it as well.

Total project value

9 120 743,55 PLN

EU co-financing

6 547 980,62 PLN

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