Multi-stage vaccine fermenter (GMP)

Industrial Fermenter: Beyond a Machinery: Industrial Fermenter Role

Special industrial fermenters are devices optimized to perform microbial fermentation and cell culture fermentation in bulk. They are the most important and most utilized equipment in fermentation industry- otherwise known as the heart of the operation. Serving as an intermediate between raw materials and end products, they convert simple basic expression (substrates) into medicines, vaccines, enzymes and chemicals of high value.

Haven’t you heard?

• Laboratory fermenters minimize production as a rule between 2 to 500 liters.
• Pilot fermenters ferment between 500 and 5000 liters.
• Industrial, or real, fermenters begin at more than 5000 liters and up to tens of thousands.

What relevance does this scale have? Since at volume production everything has to be accurate: sterilization, mixing, oxygenation, temperature, and pH. And the Multi-stage vaccine fermenter(GMP) meets these requirements with engineering excellence.

Why Choose the Multi-Stage Vaccine Fermenter(GMP)?

Have you ever wondered: What is actually different between a world class fermenter and a regional? And here is why this fermenter is outstanding:

• Sealed and maintenance free system to avoid contamination.
• The part of mechanical seals that get rid of the risk of bacterial contamination is the double-end seal.
• Small, modular architecture combines all systems of vital importance.
• They are flexible to use mechanical or magnetic stirring.
• Superior polishing (Ra≤0.4) for easy cleaning and sterility.
• Siemens 10-inch touch screen PLC control, data logger, analysis and real-time display.

The GMP approved and designed fermenter improves safety, repeatability, and compliance of every batch.

A Breakdown of Technical Parameters: What Is Inside?

Here’s a closer look at the heart of the Multi-stage vaccine fermenter(GMP):

Parameter	Description
Total volume	5L,10L,15L,20L,30L,50L,100L,200L,500L,1000L, 2KL,5KL,10KL etc.
Working volume	30%~70%
Polishing	Electrolytic polishing, precision: 0.2-0.4um.
Stirring system	Mechanical drive or Magnetic drive, 3 height adjustable six – blade stirrer Stir speed: 50~1000rpm/50-350rpm
Sterilization	On-site sterilization(SIP) by auto control
Clean	Clean in place (CIP) by spray ball
Aeration flow	Multi-way ventilation. Auto control by mass flow meter, 1vvm
Feeding	Automatically feeding by fixed peristaltic pump (standard) Variable speed peristaltic pump(optional)
Anti-foam control	Automatically add antifoam by peristaltic pump
Temperature control	Auto-control, electric heating range: water source add 5℃ to 70℃
PH control	2.00-12.00±0.05pH, auto-control by adding acid and base, pH sensor (Hamilton/Mettler, Switzerland)
DO control	0-150±3% displaying precision 0.1%, DO sensor from Hamilton/Mettler, Switzerland. DO coupling with agitation, oxygen.
Sampling valve	Can sterilization separately, manual
Harvest	Zero dead zone bottom valve, can sterilization separately, manual
Weight system	Mettler-Toledo, Switzerland
Pressure	Auto control, BD Germany pressure transmitter or Lambert differential pressure liquid level gauge.
Exhaust	Have condenser before exhaust, control by diagram valve / Proportional control valve.
Control parameters	10in touch screen, Siemens PLC control system with control parameters (stirring, pH, DO, temperature, feeding, gas etc.), data analysis, data logging, data output and printing, overrun alarm, language switching and other functions
Optional configuration	O2/N2/CO2 gas control, Level sensor, OD sensor, Turbidity sensor, ORP sensor, Weight system, Live cell sensor etc.

Construction of Reliability and GMP Compliant Building

The biggest risk that occurs during the production of vaccines and other essential bio products is contamination. That is why this fermenter is:

• Full seal:Zero-leakage equipment to seal the process.
• Double-end mechanical seal:It blocks the entry of bacteria.
• Mirror like polishing:few-way residual contamination and increase the effectiveness of CIP/SIP.
• Combined sensors:pH, DO, temperature, foam – they are all automated sensed and controlled.

Then ask yourself, would you not have a more confident team knowing that all the parameters are traceable, controlled, and logged?

Cutting Edge Control at Your Fingertips

With a German Siemens S7-200 PLC and a 10 inches’ touch screen:

• See, log and analyze any data.
• Regulate the agitation rate, pH, DO, temperature and gas flow.
• Export compliant reports.
• Multi-language interface (English, Chinese, others).
• Alarm circuits to sense over run or abnormal situation.

In the new GMP plants data integrity and real time monitoring will be just as important as mechanical reliability and once again, this fermenter is exceptional in both of those aspects.

Adjustable Stirring

When the processes are considered, each one is unique. That’s why the Multi-stage vaccine fermenter(GMP)offers:

• Direct mechanical mixing:High, energetic mixing of viscous cultures.
• Magnetic coupling stirring:Lowers presence of mechanical seals and possibility of contamination.

And three height-adjustable six-blade stirrers make it possible to optimize oxygen transfer and mixing of bacteria, yeast, fungi, or mammalian cells.

Applications: Designed to What Matters most

What is the path of this fermenter in improving your process?

• Vaccines of animals:Avian influenza, Foot-and-mouth disease, Rabies, PRRS, DTP, Tetanus, etc.
• Human vaccines:Hepatitis B, Meningitis, Pneumonia IV, Diphtheria, and so on.
• Microorganism culture:yeast, fungi, bacteria.
• Mammalian cell culture:CHO, 293 and others biologics.
• Algae and plant cells:Nutraceuticals, pigments and food ingredients.
• Enzymes, proteins Industrial enzymes, specialty proteins.

Feed additives and veterinary antibiotics: precision fermentation of chemicals with high values.

What Makes a Multi-Stage Design So Valuable?

Did you ever think of the benefit of having several stages of fermentation in one system?

• Increased productivity:Increase the number of ferments in sequence to increase its yield.
• Flexibility:Flip flop between batch, fed-batch or continuous.
• Autonomous tanks:these can be sterilized and washed individually.

The flexibility implies its quicker scale-up, easier technology transfer, reduction of production bottlenecks.

The Importance of Industrial Fermenter

So why does it matter? Let us consider again: An industrial fermenter is a large tank, but it is a lot more than that. It is the connection of your research to production. It must:

• Survive steam sterilizing Machine
• Keeping the dead corners at a minimum
• give high quality material and energy transfer
• Make clean-up quick and minimize contamination

This is how it can really be the heart of the fermentation process.

Have You Considered Benefits of These?

• Would it not be simpler when your data is automatically logged and exportable?
• Imagine spending less time cleaning because of the smooth surfaces that are polished.
• Just imagine being able to ship contamination-free production after production.
• What would it be like to have your team to make settings in real time and with a full trace back?

These are not mere technical specs these are straight forward answers to the GMP production day to day problems.

Optional Build Your Perfection Fermenter: Standard Configurations

Each process is unique and so you can add:

• CO 2 vs N 2 vs O 2.
• Sensors; Turbidity, live cell, OD, ORP.
• Real time weighting systems.
• High tech alarms and remote control.
• Compliance data printing of batches.
• Everything fits together and is supported by Siemens PLC technology.
• Nice to look at, small and user friendly

On top of performance, this fermenter is:

• Small in size so that space is saved.
• The modularity, to be upgraded easily.
• Touch screen that is operator friendly.

The design is that of a professional appearance within any GMP plant.

Details even of permitting little give and take count: the condenser pre exhaust, the proportioning valves, the windows through which you can watch the mechanism at work.

Global Leaders Rely On Them

We are making processes all over Asia and Europe with fermenters at BaiLun Bio. Our reputation is to be quality, service and support- installation training and maintenance.

The Journey of Pilot to Production

Whether you’re scaling up from lab fermenters (2–500L), pilot fermenters (500–5000L), or moving to full industrial batches (5000L+), the Multi-stage vaccine fermenter(GMP) adapts to your process.

Summary: Why the Multi-Stage Vaccine Fermenter(GMP) is Your Next Step

• One hundred percent design in line with GMP.
• Real time information, sophisticated PLC control.
• Completely leak free, contamination free structure.
• Flexible process option in multi-stages.
• High quality polishing and CIP/ SIP cleaning.
• Large variation of size and structure.

Are You Upgrading Ready?

Selecting the best fermenter is selecting quality, efficacy and tranquility. The Multi-stage vaccine fermenter(GMP) delivers all three.

Shall we talk about your process requirements, ask what you need and where to install it. At BaiLun Bio, we convert your problems to solutions.