Preventive maintenance is one of the most effective ways to maximize the performance, reliability, and lifespan of bioprocessing equipment. Whether used for process development, pilot-scale production, manufacturing, or tangential flow filtration, ÄKTA™ chromatography and filtration systems are designed to deliver precise, repeatable performance. However, like any critical process equipment, maintaining that performance requires a structured approach to care and maintenance.
Why preventive maintenance matters
In bioprocessing environments, unexpected equipment downtime can result in lost productivity, delayed batches, increased operating costs, and potential compliance concerns. Preventive maintenance helps reduce the risk of unexpected breakdowns, keeps equipment operating according to specification, and supports long-term system reliability. It also provides documented evidence that critical functions have been tested and verified, supporting traceability in regulated environments.
Routine maintenance activities typically include:
- Functional performance testing
- Inspection of critical components
- Calibration and verification of sensors
- Replacement of wear-and-tear parts
- Verification that the system is operating within specification
- Documentation of completed activities and test results
Focus on the components that matter most
Across the ÄKTA systems portfolio, many of the same components have the greatest influence on performance and reliability.
Pumps
Pumps are at the heart of every chromatography and filtration process. Over time, pump seals, diaphragms, membranes, and related wear parts can deteriorate through normal use. This can lead to inconsistent flow rates, pressure fluctuations, inaccurate gradients, or unplanned downtime. Regular inspection and replacement of pump wear parts help maintain reproducible process performance.
Valves
Valve performance directly affects flow path selection, buffer management, and fraction collection. Continued wear on valve membranes, rotors, stators, and seals can lead to leakage, inaccurate positioning, or cross-contamination risks. Routine valve testing and replacement of valve wear parts helps ensure proper fluid path control throughout the process.
Sensors and monitors
Pressure, conductivity, pH, UV, temperature, flow, and air sensors provide the data used to monitor and control a process. Sensor drift or component degradation can affect process decisions and product quality. Regular verification and calibration help maintain confidence in critical process data.
Fluid-contact components
O-rings, gaskets, diaphragms, filters, and other elastomeric components are subject to wear, cleaning cycles, solvent exposure, and process stresses. Replacing components before failure helps reduce the risk of leaks, contamination, and process interruptions.
What should be checked during maintenance?
Comprehensive maintenance programs typically include inspections of:
- Pump performance and flow consistency
- Pressure system operation and system integrity
- Sensor calibration
- Mechanical condition and safety functions
- Software configuration and operational logs
- Overall system performance verification
For larger manufacturing systems such as ÄKTAprocess and ÄKTA process™, maintenance may additionally include hydrostatic leakage testing, emergency stop verification and process line inspections.
Adjust maintenance frequency to equipment usage
There is no single maintenance interval that suits every operation. The right schedule depends on system utilization, process demands, and the chemicals used during operation.
General guidance includes:
| Equipment utilization | Typical maintenance frequency |
|---|---|
| Up to 2000 operating hours per year | Annual or biennial maintenance depending on system type |
| 2000–4000 operating hours per year | Annual maintenance |
| More than 4000 operating hours per year | Twice-yearly maintenance |
| Applications using aggressive solvents | More frequent maintenance may be advisable |
These recommendations vary by system and process requirements, so maintenance schedules should be reviewed with qualified service personnel.
Warning signs that maintenance may be overdue
Operators should not wait until a failure occurs before taking action. Common indicators that a system may require maintenance include:
- Increasing system pressure or pressure instability
- Unexpected pump pulsation
- Sensor alarms or inconsistent readings
- Excessive wear on moving components
- Recurring software or hardware error messages
- Increased downtime or troubleshooting requirements
Many of these issues can be identified and corrected during planned maintenance before they affect production schedules.
Documentation is as important as the maintenance itself
In regulated environments, maintaining accurate service records is critical. Standardized maintenance documentation provides traceability, supports audits and inspections, and creates a historical record of equipment performance. Service reports documenting inspections, tests, calibrations, and component replacements help demonstrate that systems continue to operate as intended.
The long-term value of preventive maintenance
For bioprocessing organizations operating chromatography and filtration systems, preventive maintenance should be viewed not as a reactive expense, but as a proactive investment in operational excellence, compliance, and process performance.
If you are looking to strengthen your approach to equipment maintenance, improve system reliability, and build confidence in troubleshooting, consider participating in an original equipment manufacturer (OEM)-led maintenance and troubleshooting training program. These training courses are designed to help users better understand system operation, identify and resolve common issues, perform routine maintenance tasks, and recognize early warning signs before they lead to unplanned downtime. By developing in-house expertise, teams can improve equipment performance, reduce the need for service interventions, increase productivity, and support more consistent and reproducible results. Our training programs combine practical, hands-on learning with expert guidance from experienced instructors, helping users maximize the value and lifespan of their equipment.
Additional resources
To learn more, explore additional resources to download related content, read other articles on service offerings, or connect directly with a member of the services team to discuss your specific needs.
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