Surfactants are indispensable in the production of biologics, vaccines, and cell therapies. Yet for years, they’ve posed a persistent challenge: they are notoriously difficult to monitor accurately and in real time. That challenge is now being addressed by Nirrin and its groundbreaking Atlas platform, a real-time spectroscopy solution that is reshaping how biomanufacturers measure and manage surfactants.

In this episode of The Cell Culture Dish podcast, Editor Brandy Sargent spoke with Bryan Hassell, Founder and CEO of Nirrin, and Hannah Furrelle, Analytical Scientist at the company, to discuss the science behind Atlas and its implications for bioprocessing.

Real-Time Data Without Compromise

At the core of Atlas’s innovation is its ability to provide high-quality quantitative data in under a minute—without any sample preparation. “The real breakthrough with Atlas is speed with confidence,” explained Hassell. “Time to market for biopharma is increasingly critical, yet a lot of critical decisions still rely on data from assays that take days or even months. Atlas changes that.”

Unlike traditional techniques, which often require significant sample manipulation and suffer from matrix interference, Atlas uses high-precision tunable laser spectroscopy to directly analyze samples in their native form. “What makes Atlas so powerful is that we’re looking at the sample without altering it,” Furrelle explained. “That means the data we get is true to the process—there’s no distortion from prep steps or artifacts introduced by the method.”

Moving Beyond PLS: A New Modeling Approach

One of the technological breakthroughs enabling this leap in performance is Nirran’s move away from PLS models in favor of an iterative optimization framework. This approach eliminates the need for extensive training data, reducing model complexity while increasing robustness and flexibility.

“Where a PLS model might need 20 to 30 bioreactor runs to build a dataset, Atlas delivers data on the fly,” Hassell said. “It’s not only faster, it’s more robust, more compliant, and more versatile—especially for applications like scale-up or tech transfer, where traditional models often break down.”

Applications Across the Biomanufacturing Workflow

Atlas is already being integrated into real-world bioprocessing environments, including both batch and continuous manufacturing. In batch processes, manufacturers use Atlas to confirm critical parameters—like protein and excipient concentrations—before proceeding to the next unit operation. This enables earlier course corrections and helps prevent downstream failures.

“In the past, you either waited days for lab results or moved forward at risk,” said Hassell. “Atlas provides the immediate answers needed to make confident decisions in the moment.”

For continuous manufacturing, the value is equally profound. Atlas provides the real-time, quantitative feedback necessary for dynamic process control. “You can’t have continuous processing without real-time data,” he said. “Atlas gives you the insights needed to support real-time decisions at every step.”

Eliminating Risk with No-Prep Analysis

One of Atlas’s standout features is its ability to deliver no-prep analysis. This eliminates sources of variability that often arise during sample handling and processing.

“We’re scanning samples in their native form,” said Furrelle. “That means what we’re measuring reflects what’s actually in the process—without distortion from dilutions or centrifugation.”

This no-prep capability also speeds up workflows and eliminates risk by allowing operators to verify component concentrations instantly before committing to the next step in production.

Laying the Foundation for Smart Biomanufacturing

Nirrin sees Atlas not just as a data tool, but as a stepping stone to smart biomanufacturing. Although full automation isn’t yet widespread, Atlas is helping to lay the groundwork by delivering trustworthy real-time data, something most operations have historically lacked.

“Right now, we’re focused on validating the technology and educating the industry,” said Hassell. “Without sensors like ours, you can’t have smart manufacturing. But once real-time data becomes available, everything else,automation, digital twins, AI,can start to fall into place.”

Furrelle agreed, adding, “You can’t automate without sensors. Atlas gives you real-time insights that teams can actually use, not work around.”

From QC Tool to Strategic Platform

As teams adopt quality-by-design (QbD) approaches, Atlas is being used well beyond its initial QC role. It’s becoming a platform for optimizing surfactant levels, improving batch-to-batch consistency, and proactively preventing formulation issues.

“You can’t have quality if you don’t start from a place of quality,” Furrelle said. “Validating components before you use them is no longer just ideal, it’s achievable.”

Supporting Regulatory Compliance and GMP Readiness

With growing expectations around regulatory compliance, Atlas offers distinct advantages for GMP workflows. By capturing data directly from the process, without modification, it ensures traceability, eliminates method error, and delivers reproducible results.

“Getting data that wasn’t previously accessible is foundational to compliance,” said Furrelle. “Most of the time, we assume buffer concentration is correct based on scale readings and signatures. With Atlas, you can actually measure and prove it.”

Hassell added that Atlas’s direct-measurement capability enhances confidence in audits and inspections. “When you can take a sample straight from the line and analyze it without modification, you eliminate layers of error. That’s critical for compliance and it’s something our customers are really gravitating toward.”

Built for Sustainability and Greener Excipients

Atlas also aligns with the industry’s increasing focus on sustainability. Its optical system requires no consumables, a rare feature in today’s single-use-dominated industry. “We deliberately avoided a consumables-based model,” Hassell said. “Our customers want tools that align with their long-term goals and sustainability is a big part of that.”

The platform also supports real-time validation of novel excipients, including greener alternatives. Its broad spectral range is packed with chemical information, enabling confident measurement of even chemically distinct surfactants.

“We’ve had great success supporting teams developing new excipients,” said Hassell. “The system’s flexibility and depth of information make it future-proof.”

Real-World Impact: Surfacing Hidden Issues

Early use cases illustrate the power of the platform. In one of the first beta tests, a biopharma team used Atlas to trace a suspected surfactant stability issue. “They didn’t know where the problem started, but within minutes, we helped them pinpoint exactly where the formulation went off track,” said Hassell. “It was a powerful example of real-time debugging.”

Furrelle recalled a similarly impactful use case involving ultrafiltration and diafiltration (UF/DF). “Traditionally, you wouldn’t know if you lost or enriched an analyte until after the step was complete. Atlas allows you to monitor the process live and optimize it. That’s a huge advance.”

A Broader Role in Process Development

With increasing adoption, Atlas is quickly evolving into a comprehensive process platform. “I’ve always thought of it as more than QC,” said Furrelle. “It’s helping teams move from retrospective quality control to proactive process design.”

More teams are now asking not just whether a step worked, but how to improve it. Atlas provides the data needed to make those decisions in real time.

What’s Next for Nirrin and Atlas

As of now, Nirrin is focused on validating the technology and supporting its integration into real-world workflows. With backing from the NIH and a growing customer base, the company has no shortage of momentum.

While the current focus is on protein-based therapeutics, Nirrin is already preparing for broader applications. “We have line of sight into other modalities, like cell and gene therapies,” said Hassell. “But first, we want to solve the problems in front of us really well and help the industry move forward with confidence.”

Looking Ahead: The Future of Surfactant Analytics

Both Hassell and Furrelle are confident that Atlas will play a central role in the future of surfactant monitoring. “We want Atlas to be the go-to instrument for companies developing new formulations,” said Hassell.

Furrelle emphasized the importance of robust analytics during tech transfer. “Right now, that hand off is often based on assumptions and broad specs. With Atlas, you can measure exactly what’s happening and that changes everything.”

Conclusion

Atlas isn’t just solving an old problem, it’s setting a new standard. With its speed, accuracy, and no-prep design, it’s enabling smarter biomanufacturing, better compliance, and more sustainable practices. As the industry moves forward, Atlas stands poised to become an essential platform for quality, innovation, and transformation in bioprocessing.

See Atlas in Action: https://www.nirrin.tech/nirrin-atlas-evaluation-contact-us/