Abstract: Process control of continuous production of biomolecules is a major challenge due to complex nature of processes and time scales of operations involved. Availability of key process variables in real-time is one of main requirements. This disclosure relates to a processor implemented method of controlling a continuous bioprocessing plant which includes at least one of: receiving, an input data associated with one or more equipments; generating, by a recipe builder, a sequence of unit operations to determine at least one job order based on the at least input data; obtaining, a control decision associated with a control parameter based on the at least one job order; communicating, via the middleware, the control decision associated with the control parameter to the PLC; and executing, by a control system of the PLC, the control decision on a unit equipment to control: (i) a continuous bioprocessing train, and (ii) an individual unit operation.

Abstract: Described herein is a surge tank based system to control surge tanks in a manufacturing train. The system includes data acquisition unit, data normalization unit, deviation identification and handling unit and an real time execution of control action from centralized computer in a manufacturing process unit, wherein said manufacturing unit includes an integrated system which incorporates a plurality of pumps, surge tanks, and weighing balances, and other unit operations alongside the normal unit operations of production of output product.