Integrated Thermal Solutions for Biopharma Process Reliability
Watlow and Eurotherm deliver integrated heater and control solutions that enhance process reliability and compliance across biopharma applications
Navigating the Rapid Evolution of Biopharma Processes
Biopharma manufacturing is being reshaped by continuous processing, digitalization, flexible single-use systems, and a growing focus on sustainability.
Shift to continuous and intensified processing
Moving from batch to continuous biomanufacturing to reduce cycle times, improve consistency, and lower cost.
Digitalization, advanced analytics & AI / ML integration
Digitalization, advanced analytics & AI / ML integration.
Adoption of modular & single-use / hybrid systems
Flexible facility design, disposable systems, and hybrid (single-use + stainless) architectures to scale more rapidly and reduce contamination risk.
Sustainability, resource efficiency & regulatory pressure
Greater emphasis on energy / water reduction, waste control, and compliance with evolving global standards in biomanufacturing.Biopharma Process Applications
The following overview illustrates critical unit operations across the biopharma value chain, highlighting where precise thermal control supports process reliability and compliance.
Interactive Manufacturing Facility Diagram
Thermal Purpose:
Stabilize growth environments and monitor rooms/hoods; manage cryogenic storage
Critical to Quality (CTQ):
Temperature, CO2, relative humidity (RH), airflow/sash, data integrity
Heaters:
Polyimide | Silicon-rubber panels | Immersion | Electric duct | FLUENT® In-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls| Mini-DCS for redundant control
Stabilize growth environments and monitor rooms/hoods; manage cryogenic storage
Critical to Quality (CTQ):
Temperature, CO2, relative humidity (RH), airflow/sash, data integrity
Heaters:
Polyimide | Silicon-rubber panels | Immersion | Electric duct | FLUENT® In-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls| Mini-DCS for redundant control
Thermal Purpose:
Uniform media temperature with controlled rocking and gentle shear.
Critical to Quality (CTQ):
Temperature uniformity, rocking rate stability, batch data integrity
Heaters:
Silicone Rubber base panels | Polyimide panels | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Uniform media temperature with controlled rocking and gentle shear.
Critical to Quality (CTQ):
Temperature uniformity, rocking rate stability, batch data integrity
Heaters:
Silicone Rubber base panels | Polyimide panels | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Condition jackets/media and maintain dissolved oxygen (DO) and pH
Critical to Quality (CTQ):
Temperature accuracy, DO/pH stability, reproducible ramps
Heaters:
Silicone Rubber heating jackets | Immersion | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Condition jackets/media and maintain dissolved oxygen (DO) and pH
Critical to Quality (CTQ):
Temperature accuracy, DO/pH stability, reproducible ramps
Heaters:
Silicone Rubber heating jackets | Immersion | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Condition jackets/media and maintain dissolved oxygen (DO) and pH
Critical to Quality (CTQ):
Temperature accuracy, DO/pH stability, reproducible ramps
Heaters:
Silicone Rubber heating jackets | Immersion | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Condition jackets/media and maintain dissolved oxygen (DO) and pH
Critical to Quality (CTQ):
Temperature accuracy, DO/pH stability, reproducible ramps
Heaters:
Silicone Rubber heating jackets | Immersion | circulation | FLUENT® in-line electric heater for on-demand heat
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Condition feed temperature to manage viscosity before separation
Critical to Quality (CTQ):
Feed temperature stability, throughput, alarm history
Heaters:
Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Condition feed temperature to manage viscosity before separation
Critical to Quality (CTQ):
Feed temperature stability, throughput, alarm history
Heaters:
Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Condition product and Water for Injection (WFI) at the nozzle
Critical to Quality (CTQ):
Product/WFI temperature, alarmed deviations, batch traceability
Heaters:
Silicone Rubber | Polyimide | Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Condition product and Water for Injection (WFI) at the nozzle
Critical to Quality (CTQ):
Product/WFI temperature, alarmed deviations, batch traceability
Heaters:
Silicone Rubber | Polyimide | Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Follow precise shelf temperature and pressure profiles
Critical to Quality (CTQ):
Ramp/soak accuracy, endpoint confirmation, batch data
Heaters:
Silicone Rubber shelf panels | polyimide panels | Circulation | FLUENT® in-line electric heater for on-demand heat | Low-mass flexible heaters support uniform shelf control
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Follow precise shelf temperature and pressure profiles
Critical to Quality (CTQ):
Ramp/soak accuracy, endpoint confirmation, batch data
Heaters:
Silicone Rubber shelf panels | polyimide panels | Circulation | FLUENT® in-line electric heater for on-demand heat | Low-mass flexible heaters support uniform shelf control
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Execute timed exposures at target temperature
Critical to Quality (CTQ):
Setpoint accuracy, dwell timing, batch approval
Heaters:
Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Execute timed exposures at target temperature
Critical to Quality (CTQ):
Setpoint accuracy, dwell timing, batch approval
Heaters:
Circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Maintain a stable, uniform, and precise temperature for both the chromatography column and the mobile phase buffers throughout the analysis
Critical to Quality (CTQ):
Buffer/column temperature stability, event logging
Heaters:
Silicone Rubber | Polyimide | Cartridge or Ceramic (ULTRAMIC®) for Chromatography + Mass Spectrometry
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Maintain a stable, uniform, and precise temperature for both the chromatography column and the mobile phase buffers throughout the analysis
Critical to Quality (CTQ):
Buffer/column temperature stability, event logging
Heaters:
Silicone Rubber | Polyimide | Cartridge or Ceramic (ULTRAMIC®) for Chromatography + Mass Spectrometry
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Stabilize retentate/buffer temperatures to control flux and transmembrane pressure (TMP)
Critical to Quality (CTQ):
Temperature accuracy, TMP pressure control, batch records
Heaters:
circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Stabilize retentate/buffer temperatures to control flux and transmembrane pressure (TMP)
Critical to Quality (CTQ):
Temperature accuracy, TMP pressure control, batch records
Heaters:
circulation | FLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Electrify large utility boilers and process heaters
Critical to Quality (CTQ):
Thermal capacity, efficiency, safety interlocks, energy data
Heaters:
Low voltage immersion, medium voltage circulation
POWERSAFE™ Medium Voltage System (up to 7.2kV) reduces infrastructure complexity and costs.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Electrify large utility boilers and process heaters
Critical to Quality (CTQ):
Thermal capacity, efficiency, safety interlocks, energy data
Heaters:
Low voltage immersion, medium voltage circulation
POWERSAFE™ Medium Voltage System (up to 7.2kV) reduces infrastructure complexity and costs.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Maintain loop temperature and automate sanitize sequences
Critical to Quality (CTQ):
Loop temperature uniformity, sanitize dwell, alarm history
Heaters:
Circulation | In-line
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Maintain loop temperature and automate sanitize sequences
Critical to Quality (CTQ):
Loop temperature uniformity, sanitize dwell, alarm history
Heaters:
Circulation | In-line
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Generate and modulate clean steam for validated exposure
Critical to Quality (CTQ):
Pressure, temperature, dwell time, batch records
Heaters:
Immersion (high kW)
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Generate and modulate clean steam for validated exposure
Critical to Quality (CTQ):
Pressure, temperature, dwell time, batch records
Heaters:
Immersion (high kW)
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Thermal Purpose:
Control generation and sanitization temperature profiles
Critical to Quality (CTQ):
Setpoint accuracy, sanitize dwell profile, release records
Heaters:
Immersion | Circulation | FLLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Control generation and sanitization temperature profiles
Critical to Quality (CTQ):
Setpoint accuracy, sanitize dwell profile, release records
Heaters:
Immersion | Circulation | FLLUENT® in-line electric heater for on-demand heat.
Controls/Automation:
PID Controls | Paperless Recorders | Power Controls | Mini-DCS for redundant control
Engineered Heating Solutions for Biopharma Applications
Innovative cartridge, in-line, and flexible heating technologies precisely engineered to meet rigorous thermal requirements in biotech, pharmaceutical, and life sciences processes.
Ceramic Heaters
Ultra-fast ramp rates, high watt densities and low leakage current make this heater best suited for Medical and Clinical applications, where electrical safety, small size and cleanliness are critical
In-Line Heaters
Compact, lightweight heaters offering optimized heat transfer and superior temperature uniformity. The FLUENT® heater delivers exceptional performance and rapid response times through its high watt density.
Silicone Rubber Heater
Watlow’s silicone rubber heaters offer rigid durability and precise heat delivery, enhancing thermal efficiency and reducing energy use.
Polyimide Heater
Polyimide heater provide exceptional strength, dimensional stability, and accurate heating performance for critical biopharma applications.Integrated Thermal Solutions for Biopharma Processing
Watlow and Eurotherm deliver scalable heating, sensing, and control technologies designed specifically for biopharma environments. These integrated solutions ensure precise thermal stability, regulatory compliance, and optimized performance across single-use and modular bioprocessing applications. Innovative cartridge, in-line, and flexible heating technologies precisely engineered to meet rigorous thermal requirements in biotech, pharmaceutical, and life sciences processes.
PID Controllers
Industry-leading, integrated multi-function controllers combine temperature, process, energy, and machine control. These industry-leading controllers enhance the user experience with an interface that enables an easy setup. With configurable solutions, to meet every thermal requirement and to bring your equipment to the next level.
Modular Controller
This EZ-ZONE RM controller family is extremely flexible and scalable allowing mixing and matching of I/O for one to 152 control loops and limits, up to 256 monitor points and other controller functions including counters, timers, math, and logic in an integrated control solution.
Compact, Integrated Mini-DCS
The Eurotherm T2750 PAC is a compact, integrated mini DCS (Distributed Control System) engineered to streamline biopharma manufacturing. Unlike traditional PLC-SCADA architectures, the T2750 combines batch control, redundancy, and secure data handling in a single, scalable platform - dramatically reducing validation complexity and footprint.
Sensors
Watlow manufactures a variety of resistance temperature detectors (RTD) sensors that are specially designed to ensure precise and repeatable temperature measurement. Watlow sensors are built to meet the most demanding industrial applications while providing a lower total cost of ownership for our customers.
Integrated Thermal Loop Solutions
Watlow delivers more than individual heaters, sensors, and controllers - these components can be integrated into engineered thermal loop solutions and sub-assemblies that simplify design, reduce risk, and accelerate time to validation
The Value of Thermal Loop Solutions
By combining heaters, temperature sensors, power controllers, and advanced process control into pre-engineered sub-assemblies, Watlow ensures optimal thermal performance and process reliability. These integrated solutions minimize installation complexity, improve system efficiency, and support compliance with biopharma standards by providing validated, repeatable temperature control loops. Whether delivered as modular skids, plug-and-play thermal assemblies, or customized sub-systems, Watlow’s thermal loops are designed to shorten project timelines and lower total cost of ownership
Global Reach, Local Manufacturing
With world-class manufacturing, development, and service centers strategically located worldwide, Watlow ensures in-region supply, faster response, and reliable support for biopharma customers
Insights & Impact
Evidence, expertise, and events driving innovation across the biopharma industry.
Held November 24–25 in Vösendorf, Austria, AUTOMA+ 2025 marks the 5th anniversary of this exclusive B2B event focused on driving digital transformation in the pharmaceutical industry.
Bringing together leaders from pharma, biotech, CMOs/CDMOs, equipment manufacturers, and technology providers, the program dives into real-world use cases across R&D, manufacturing, packaging, lab automation, supply chain, and more.
Bringing together leaders from pharma, biotech, CMOs/CDMOs, equipment manufacturers, and technology providers, the program dives into real-world use cases across R&D, manufacturing, packaging, lab automation, supply chain, and more.
Advanced ceramic heaters, like Watlow’s ULTRAMIC®, give analytical equipment designers a modern alternative to outdated metal-sheathed technology. They are smaller, faster-responding, more precise, and resistant to contamination — helping manufacturers improve performance, enable innovative designs, and accelerate time to market.Compact, lightweight heaters offering optimized heat transfer and superior temperature uniformity. The FLUENT® heater delivers exceptional performance and rapid response times through its high watt density.
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Decarbonization efforts worldwide, led both by industry leaders and legislation, have increased efforts to shift fossil fuel use to renewables. One way many industrial organizations can embrace this – and already have – is by shifting process heater systems from fuel-burning to electric.
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Freeze drying (also known as lyophilization or cryodesiccation) is a slow batch process used in pharmaceutical and biotechnology industries (such as diet food production) to extract dry product from an aqueous solution. The resulting powder material can be easily stored, shipped, and later reconstituted for use in products such as solid dose tablets and soluble solutions.
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Connect With Our Experts
Connect with Watlow to discuss your biopharma thermal control needs and explore how our solutions can support your process reliability and compliance