Introducing the Industrial Scale Fermenter/Bioreactor

So why is this Industrial Scale Fermenter/Bioreactor the heartbeat to so many productive bioprocessing plants? So how about we examine up close.

The Industrial-Strength of Biotechnology

With any industrial manufacture of product, be it enzymes, vaccines, antibiotics, proteins, bio-based chemicals, the fermenter is more than a piece of equipment. It is that important link between raw materials and finished products.

The Industrial Scale Fermenter/Bioreactor is a specifically designed product to do this task that supports batch, fed batch or continuous operation and it can be sterile, efficient and reproducible. Envision a high quality, high power automation controlled design and flexibility in a fermenter but with an industry robust 5000L; and you have the dream come true. That is what we bring about.

What Is Important about Industrial-Scale Fermentation?

When it comes to the active field of biotechnology and industrial microbiology, the biggest challenge, to say the least, is making the necessary scale-up process from the laboratory bench to the full-scale production. A successful pilot run means nothing if your industrial system can’t replicate those results reliably. Here the Industrial Scale Fermenter/Bioreactor will perform the best, which is the integration of process control, rugged, and simple to clean and sterilize all in one solution.

Does your manufacturing line have problems such as contamination, uneven yields or energy wastage? Now, how does this bioreactor assist in breaking such boundaries?

The Outstanding Functions and Design

The philosophy of the design is straightforward for our Industrial Scale Fermenter/Bioreactor: no detail is too small, yet should have been optimized to support microbial or cell cultures with maximum productivity and safety. These are the important aspects of the design to consider:

• 316/304 stainless steel jacketed tanks with polished service side to 0.4-0.6 microns to enable clearance and low contamination chance.
• Advanced stirring systems (mechanical or magnetic) to handle different viscosity media and delicate cultures.
• Fully automated SIP (sterilization in place) and CIP (cleaning in place) systems to reduce downtime.
• Siemens PLC control and online control of real-time storage, monitoring of data and advanced control techniques.
• Adjustable gas control covering Air, O2, N2 and CO2.

And now you will ask me how this can be of any practical assistance in training? Let us go more into details.

Technical Parameters

What makes the Industrial Scale Fermenter/Bioreactor a production ready solution is as follows:

Parameter	Description
Total volume	5L,10L,15L,20L,30L,50L,100L,200L,500L,1000L, 5KL, 50KL, 200KL etc.
Working volume	30%~70%
Tank	Jacket tank, made by SS316 and SS304, tank design pressure 0.3Mpa, jacket design pressure 0.35Mpa, polishing 0.4-0.6um, ratio of diameter and height is 1:2.2-2.5
Stirring system	Mechanical drive on the top/bottom or Magnetic drive on the top, 3pcs height adjustable six-blade paddle Stir speed: 50~1000rpm/50-400rpm
Sterilization	Sterilize in place(SIP), auto control by program
Clean	Clean in place (CIP) by spray ball
Gas control	Control by rotor meter, air flow 1 vvm
Feeding	Automatically feeding by peristaltic pump
Anti-foam control	Automatically add antifoam by peristaltic pump
Temperature control	Auto-control,  electric heating range: water source add 5℃ to 70℃
PH control	PH 2.00-12.00±0.1, auto-control adding acid/base by peristaltic pump, pH sensor from Hamilton/Mettler, Switzerland.
Do control	0-150±3% displaying precision 0.1%, DO sensor from Hamilton/Mettler, Switzerland. DO coupling with agitation, oxygen.
Sampling	Sampling valve, can sterilization separately, manual
Harvest	Zero dead zone bottom valve(Gemu/Burket,Germany), can sterilization separately, manual/auto
Lid lift system	30L-500L have lid lift system, 700-1000L have human hole.
Pressure	Auto control, BD Germany pressure transmitter
Exhaust	Have condenser before exhaust, control by diagram valve / Proportional control valve.
Control parameters	10 or 15 inch touch screen , Siemens PLC with control parameters (stirring, pH, DO, temperature, feeding, alarm, gas etc.), data analysis, data record, data output, language(RU/EN/CN) and other customized functions
Optional configuration	Remote control, Mass flow meter(auto control gas), O2/N2/CO2, gas flow 2vvm, gas(CO2) exhaust analysis, Level sensor, Turbidity(OD) sensor, ORP sensor, Weight system, Live cell sensor(Biomass), Printing, Siemens touch screen, Double mechanical seal, 4-Valves-group for feeding, Bottom valve auto discharge, ASME certificate, CSA certificate, Batch culture, Seed transfer, etc.

Process Reliability: The Center-piece of Industrial Manufacture

Consider the bets: a contaminated 5000L fermenter will result in massive material loss and time wastage. Such issues are avoided by this system in the following way:

• Many smooth inside welds and smooth polished interiors in order to avoid dead corners.
• SIP and CIP systems that are completely automated with assurance of effective sterilization and cleaning.
• Alarm system and sensor integration to detect the deviations in the process in real time.

Today, ask yourself how much money you would save only by eliminating even one case of contamination per year.

State-of-Art Automation and Control

The Industrial Scale Fermenter/Bioreactor does not only provide strong mechanical design, but it also provides the best control available in the industry:

• The Siemens PLCs coupled with touch screens easy to use.
• The parameters such as pH, DO, temperature and agitation speed could be monitored in real time.
• Compliance and optimisation of process with data logging and export.
• Automatic feeding and antifoam to get stable production.

This implies that your operators have to make fewer setting changes, and more time enhancing process results.

Flexible Stirring and Gas handling

The system is appropriate to both mechanical and magnetic stirring, all the way to highly viscous fungal cultures as well as shear-sensitive mammalian cells:

• Sealed operation is guaranteed as there is magnetic coupling which minimizes the chances of any contamination.
• Paddles are six bladed to maximize the mixing and oxygen transfer.
• Gas control aids the sophisticated applications:
• Inputs of air, oxygen, nitrogen and CO2.
• Auto gas blending optional mass flow meters.
• Exhaust condenser ensures that the products are not lost and minimizes vents.

Versatility and Scalability of Production

The BODREAD V2 system is a versatile and scalable medium-sized production grid. Regardless of the type of product you are yielding, antibiotics, amino acids, vaccines, or enzymes, the Industrial Scale Fermenter/Bioreactor is versatile on the basis of process modes:

• Batch culture.
• Fed-batch culture.
• Continuous and perfusion system.

An optional module, such as live cell sensors, weight systems and ORP sensors, enables you to optimize your process.

Construction to World standards

The system is trans-national market oriented:

• Options of certification to ASME and CSA.
• Brand-name components; Siemens, Hamilton, Mettler, Gemu, Burket, and BD.
• Interface language and Software customization.

Not only has been built to work-but to do it so well wherever you are operating.

The Energy efficiency and Sustainability

The cost of energy may be a huge challenge to profitability. There is a jacketed design and effective heating and cooling that save on thermal loss. The CIP system diminishes use of water and cleaning agent.

Consider this: what could happen to utility expenses should your fermenter cut on the cost of utilities without affecting performance?

Applications of It in the Real World

How are Industrial Scale Fermenter/Bioreactor used by the industries?

• Vaccine manufacturing (human and veterinary).
• The manufacture of enzymes into food and industry.
• Organic acid and amino acids.
• Antibiotic fermentation.
• Recombinant proteins manufacture.

It is so versatile that it underpins both multinational production plants and the biotech startups.

Intuitive Operation: Operator based Design

Usability can provide to any system even the most advanced one:

• Easy-to-read displays having 10-15inch touch screens.
• Multi-lingual menu and graphical data presentations.
• Monitoring remotely eliminates the requirement of people on the locations.
• The curves of historical data are used to debug the processes and minimize flaws.

How many hours would your team have saved on a user-friendly system?

On-the-fly Safety and Compliance

Interlocked and built-in warnings safeguard your goods, machines and employees:

• Overpressure automatic shut-to-off.
• Alerts over temperature, pH and DO variances.
• Convenience in export of data in regulatory audits.
• Nothing unexpected except stable production.
• Viable investment in the future

Your production requirements can increase. You can get the modular structure of the Industrial Scale Fermenter/Bioreactor:

• Mass flow control as opposed to rotor meter.
• Include exhausts gas analysis CO2.
• Install level sensors, turbidity and biomass sensors.
• Increase in single batch to seed transfer systems.
• It is a system that is scalable with your business.

Why BaiLun Bio?

With decades of experience BaiLun Bio only supplies equipment:

• Consulting and design of processes.
• After sale services and training.
• Globally shipping and set up.
• Custom made remedies to unique use.

We understand fermentation isn’t just equipment, it’s your business.

Final Thoughts

The Industrial Scale Fermenter/Bioreactor is not a product only. It is the man to:

• Increases of the yields of products.
• Unity in quality of batches.
• Reduced downtimes and reduction of contamination.
• Energy and resources efficiency.
• Easy to use control.

Ask yourself the question: is your process more cost effective, prolific, and profitable with improved equipment?

It is time to make your production to the next level. Contact BaiLun Bio to understand how the Industrial Scale Fermenter/Bioreactor can create wonders in your operations.

Are you craving to grow with confidence? How about we create fermentation of the future.