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 Многоступенчатый ферментер вакцин (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):

Параметр	Дописание
Общий объем	5Л,10Л,15Л,20Л,30Л,50Л,100Л,200Л,500Л,1000Л, 2КЛ,5КЛ,10КЛ и т. д.
Рабочий объем	30%~70%
Полировка	Электролитическая полировка, точность: 0,2-0,4 мкм.
Система перемешивания	Механический или магнитный привод, 3 регулируемые по высоте шестилопастные мешалки Скорость перемешивания: 50~1000 об/мин/50-350 об/мин
Стерилизация	Стерилизация на месте (SIP) с автоматическим контролем
Чистый	Очистка на месте (CIP) с помощью распылительного шарика.
Поток аэрации	Многоходовая вентиляция. Автоматическое управление по массовому расходомеру, 1ввм
Кормление	Автоматическая подача с помощью стационарного перистальтического насоса (стандартно) Перистальтический насос с регулируемой скоростью (опция)
Контроль пенообразования	Автоматическое добавление пеногасителя с помощью перистальтического насоса.
Контроль температуры	Автоматическое управление, диапазон электрического нагрева: источник воды добавляет от 5 ℃ до 70 ℃.
контроль рН	2,00-12,00±0,05pH, автоконтроль путем добавления кислоты и основания, датчик pH (Hamilton/Mettler, Швейцария)
ДЕЛАТЬ контроль	0-150±3%, отображающий точность 0,1%, датчик растворенного кислорода от Hamilton/Mettler, Швейцария. Соединение DO с перемешиванием, кислородом.
Пробоотборный клапан	Можно стерилизовать отдельно, вручную.
Урожай	Нижний клапан с нулевой мертвой зоной, стерилизация банок отдельно, ручное управление
Весовая система	Меттлер-Толедо, Швейцария
Давление	Автоматическое управление, датчик давления BD Germany или датчик уровня жидкости Lambert при перепаде давления.
Выхлоп	Перед выпуском имеется конденсатор, управление осуществляется с помощью клапана схемы/пропорционального регулирующего клапана.
Параметры управления	10-дюймовый сенсорный экран, система управления ПЛК Siemens с параметрами контроля (перемешивание, pH, раствор кислорода, температура, подача, газ и т. д.), анализ данных, регистрация данных, вывод и печать данных, сигнализация о переполнении, переключение языка и другие функции.
Дополнительная конфигурация	Контроль газа O2/N2/CO2, датчик уровня, датчик OD, датчик мутности, датчик ОВП, система взвешивания, датчик живых клеток и т. д.

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 Многоступенчатый ферментер вакцин (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 БайЛун Био. 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 Многоступенчатый ферментер вакцин (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 Многоступенчатый ферментер вакцин (GMP) delivers all three.

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