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.

A controller is configured to control a system by generating a control input to an actuator changing a state of the system in accordance with the control input. The controller includes an interface configured to receive data indicative of dynamic response of the actuator and a tuner configured to determine the maximum rate of change of the control input during a control cycle using the received data indicative of dynamic response of the actuator. The controller also includes a receiver configured to receive measurements of the state of the system and a solver configured to determine a current value of the control input for controlling the controlled system based on the state of the controlled system subject to constraints on operation of the system and a constraint on the maximum rate of change of the control input, and to cause the actuator to change the state of the system according to the current value of the control input.

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.

A programmable logic controller (PLC) is connected to another PLC. The PLC includes a communicator that receives an access event from an external device and performs communication through a network, a storage that stores access information about the access event, a sharer that provides the access information to the other PLC and acquires, from the other PLC, access information about an access event to the other PLC through the network to share the access information with the other PLC in a form of a distributed ledger, and a processor that performs, when the communicator newly receives an exceptional access event occurring less frequently than other access events in the access events indicated by the access information, a process on the exceptional access event. The process is different from a process for the other access events.