The Ultimate Checklist to Keep Biotech Equipment Running at Peak Performance
In biotech, even small equipment issues can lead to big problems—like downtime, compliance risks, or lost batches. So at AES, we’ve developed a comprehensive maintenance checklist to help you stay ahead of issues, stay compliant, and keep your systems running at peak performance.
Table of Contents
In high-stakes biotech environments, even minor equipment issues can lead to costly setbacks. This comprehensive guide from AES outlines proactive maintenance strategies that help you stay compliant, minimize downtime, and extend the life of your critical systems, from R&D to full-scale production.
Why Proactive Maintenance Matters
In biotechnology operations—where precision, compliance, and system uptime are critical—AES provides comprehensive maintenance and service programs to ensure your equipment consistently delivers optimal performance. Our support extends asset life, minimizes downtime, and safeguards process integrity from R&D through to production.
Why Our Services Matter
In biotech operations, precision and uptime aren’t optional—they’re critical. Even small issues can trigger major consequences, like:
- Batch loss or contamination
- Regulatory noncompliance
- Production delays and rework
- Data integrity issues
That’s why AES goes beyond basic service. Our proactive maintenance and calibration programs are designed to keep your equipment running smoothly, reduce downtime, and safeguard your process from R&D through commercial manufacturing.
When your systems are reliable, your team can focus on what matters most—bringing breakthrough therapies to life.
Daily, Weekly, Monthly—What to Check and When
Daily Tasks
- Check for physical wear or damage and leaks
- Wipe down surfaces
- Look for any contamination risks
Weekly Tasks
- Review usage logs for anomalies
- Inspect seals, filters, and tubing integrity
- Clean internal surfaces (as permitted
Monthly Tasks
- Run full-system diagnostics
- Check calibration status and firmware alerts
- Log all maintenance tasks for GMP/GLP traceability
“Consistent maintenance isn’t just about performance—it’s your first line of defence against downtime.”
What AES Aftermarket Services Actually Covers
When you work with AES, you’re getting more than a wipe-down and walk-through. Our team follows GMP-compliant protocols to proactively assess, tune, and document your system. Here’s what that includes:
- Replacing wear parts (bearings, tubing, seals, O-rings, gaskets)
- Testing sensors: pH, DO, pressure, flow, temperature, conductivity
- Electrical tests: grounding, continuity, fuse checks
- Motor and agitator calibration
- Valve, alarm, and pump function checks
- Full service reports with traceability logs and next-service recommendations
AES follows OEM and GMP-compliant protocols.
Environment Matters—Cleanroom Maintenance Tips
- Use ISO-rated cleaning agents
- Log tasks for audit trails, Document everything for GMP traceability
- Monitor temperature, humidity, and airborne particles
- Use anti-static or sterilizable tools
Our engineers build for these standards. Our service team helps you meet them every day.
Don't Skip Updates
Software & Firmware Updates
Staying current means fewer vulnerabilities, better speed, and easier audits. AES keeps your systems secure and optimized by managing:
- DeltaV logic updates, control module tuning, and alarm configurations
- HMI/SCADA screen upgrades for improved usability
- Device firmware updates (e.g., Mettler Toledo, Hamilton, Endress+Hauser)
- Change control documentation with rollback procedures for validation
Why It Matters
- Security Patches: Protect connected systems from vulnerabilities
- Performance Enhancements: Improve speed, automation, and compatibility
- Bug Fixes: Prevent errors that can compromise data or operations
AES Capabilities
- DeltaV logic updates, HMI/SCADA screen upgrades, firmware patches
- Remote update deployment (with secure access)
- Full audit documentation with rollback procedures
When to Calibrate Your Equipment
Calibration & Adjustment
While AES does not offer calibration services, we emphasize the importance of routine verifications to ensure accurate readings and timely failure detection. Critical components include:
- Analog and digital transmitters (pH, DO, pressure, temperature, conductivity)
- Load cells and vessel scales
- Flowmeters (magnetic, mass, thermal)
- RTDs, thermocouples, and level probes
Signs you need calibration
- Sensor drift, inconsistent readings, error messages
- After events like relocations, power loss, or equipment changes
Recommended Frequency
- Every 3–6 months for standard use
- Monthly or before major production runs for critical systems
Note: While AES does not perform calibration, we emphasize regular third-party verification using NIST-traceable standards. Calibration should be fully documented to meet FDA/ISO/GLP requirements.
Retrofitting & Upgrades
When full equipment replacement isn’t feasible for our client, AES offers a cost-efficient path forward. Our team can deliver targeted upgrades that extend asset life, improve compliance, and support integration with modern automation systems:
- Instrumentation upgrades (e.g., analog to digital sensors)
- Electrical panel modernization for compliance
- Integration of newer communication protocols (OPC UA, Modbus TCP/IP, Profibus)
- Custom automation logic improvements in DeltaV or other DCS platforms
- VP8 cable retrofitting to enhance bioreactor connectivity
Consider Retrofitting When
- Equipment is structurally sound but outdated
- Bottlenecks in workflow due to obsolete software/hardware
- New compliance or integration needs
AES in Action: Real Results
- Client A: Retrofitted 10-year-old chromatography units—40% cost savings compared to full replacement
- Client B: Incubator upgrade for CO₂ efficiency—extended equipment life by 5+ years
- Client C: Modernized control panels—boosted SOP compliance and uptime
AES Service Model
- On-site and remote diagnostics
- Scheduling aligned with production cycles
- Complete documentation for audits and validation
Struggling with Equipment Downtime? Let AES Keep Your Biotech Systems Running Smoothly.
From daily checklists to expert service programs, AES helps you stay compliant, reduce downtime, and extend the life of your equipment—so your team can focus on advancing science, not troubleshooting systems.