500L to 2000L Bio-Fermentation Reactor Tank for Processing Line 1000L Option Available
The fermentation tank, an essential marvel also referred to as the fermentation vessel or bioreactor, transcends multiple industries, including brewing (encompassing both beer and wine), food processing, biotechnology, pharmaceuticals, and the chemical sector. It serves as a pivotal container that fosters the growth and metabolic activities of microorganisms like yeast and bacteria or various cells, including animal and plant cells. Under meticulously controlled conditions, it enables the production of a wide array of valuable products such as alcohol, enzymes, antibiotics, biofuels, and vaccines.
The design of this sophisticated fermentation tank generally encompasses the following critical components:
1.
Tank body: It provides an enclosed, sterile environment, with capacities ranging from a few liters to thousands of cubic meters. Constructed predominantly from stainless steel, the tank ensures sterility and remarkable resistance to corrosion.
2.
Stirring system: This system is indispensable for mixing contents within the tank, ensuring an even distribution of nutrients and oxygen (or carbon dioxide), thereby promoting robust microbial growth and optimal product formation. Mixers come in diverse designs, including turbine and paddle variants.
3.
Temperature control system: Maintaining the ideal fermentation temperature is vital for microorganism activity. This is expertly managed through jacket heating, cooling coils, and advanced temperature control systems.
4.
Ventilation and defoaming system: In aerobic fermentation processes, the system provides sterile air or oxygen and efficiently expels carbon dioxide and other gases. Additionally, it minimizes foam formation through the use of defoamers or specially designed defoaming mechanisms.
5.
Sensors and control systems: These systems diligently monitor and regulate numerous fermentation parameters, including pH levels, dissolved oxygen (DO), temperature, and pressure, ensuring that fermentation conditions remain optimally stable.
6.
Sampling and feeding ports: These ports are designed to facilitate precise sampling and analysis throughout the fermentation process, as well as the addition of nutrients and acid-base adjustment solutions, as necessary.
7.
Sterilization and cleaning system: Ensuring comprehensive sterilization and cleaning before and after each use, this system prevents contamination and maintains batch-to-batch consistency.
In today's advanced era, fermentation technology is predominantly automated. Many fermentation tanks now incorporate cutting-edge monitoring and data acquisition systems (SCADA), enabling remote monitoring and management to significantly enhance efficiency and product quality.
• Main technical parameters:
Coefficient of charge
|
70-75% |
Ventilation ratio
|
1-2vvm |
Height-diameter ratio
|
2-2.5 |
Tank series
|
10L;20L;30L;50L;100L;1-200m3;Customized volume available |
| Cultivation medium sterilizing type |
Actual sterilization;continuous sterilization;UHT continuous sterilization,etc. |
Culture types
|
fungus;bacterium,actinomyces |
| Culture expanding types |
single tank fermentation;multi-stage fermentation;disk-type fermentation |
| Heat exchange types |
Full jacket;dimple jacket;semicircle-pipe jacket;inner coil,inner turbulation |
| Stirring types |
turbine stirring,wide blade stirring;paddle stirring;deflector stirring,ect |
• Fermentation tank structure features:
(1) Design standard:
Meticulously crafted following the ASME clean equipment standards and complying with the stringent necessities of Pressure Vessel requirements.
(2)Inner surface treatment
Executed with mechanical polishing to achieve Ra‹0.4μm, followed by an impeccable mirror finish.
(3)Outer surface treatment
Subjected to mechanical polishing reaching Ra‹0.6μm, followed by a refined matting procedure.
(4)No blind corner treatment
Both the inner welding line and the surface undergo polishing, with structure components adopting full-length welding and subsequent polishing. Inner coil pipes utilize a stress-eliminating structure for enhanced durability.
(5)Fastener Structure: Reinforce the integrity of your system with our expertly designed fastener structure.
All fasteners employ the bolt stud balancing double acorn nuts, with PTFE material as a gasket seal, ensuring a robust and secure setup.
(6)Mechanical Seal: Experience unparalleled reliability with our cutting-edge mechanical seal technology.
Utilizing a washable and sterilized collection plate equipped with a mechanical seal, featuring a fixed and moving ring friction sleeve, guarantees that no friction debris contaminates the tank.
Sealed Pattern: Choose between a dry or wet type, with options for single end face or dual end face sealing solutions.
(7)Heat Exchange Type: Maximize efficiency with our advanced heat exchange innovations.
Available options include a Full Jacket, dimple jacket, semicircle-pipe jacket, inner coil, or inner tubulation, each tailored for optimal performance.
• Piping System Features: Designed for excellence in processing and performance.
(1) Processing Piping: Precision and purity in every connection.
Implementing ASME sanitary grade internal and external polished cleaning pipe. All welding is performed automatically with argon gas and thoroughly inspected by endoscope for perfection.
(2)Valves: Uncompromised control and safety in every flow.
Valves connected with tanks utilize a double membrane combination for enhanced reliability.
Diaphragm valves are used throughout, while all steam and compressed air valves are equipped with stop valves and sanitary ball valves for optimal functionality.
(3) Double membrane diaphragm type tank bottom valve, ensuring sterilization at the product outlet before sampling for utmost safety.
(4)Online Sterilization: Achieve pristine conditions with our online sterilization solutions.
Utilizing clean and saturated steam rigorously filtered by a 0.5μm titanium rod filter for impeccable sterilization.
(5)Sampling Method: Ensure sample integrity with advanced aseptic techniques.
Utilizing a diaphragm type aseptic sampling valve, perform online sterilization before sampling to ensure that every sample is pristine and uncontaminated.
(6)Subcultivation: Elevate your processes with comprehensive subcultivation capabilities.
The entire pipe can undergo sterilization throughout the process, with a thermometer installed for sterilization detection ensuring continuous safety and efficiency.
(7)Inoculation Method: Tailored solutions for precise inoculation control.
Choose between flame ring type or different pressure type methods, depending on your specific needs.
(8)Feeding Mode: Versatility and accuracy in every feed.
Utilize peristaltic pumps, measuring cups, and more to achieve precise and controlled feeding.
(9)Multi-stage Culture Expanding System Subcultivation: Expand your processes with confidence.
Leverage the subcultivation distributor for multitube distribution, subcultivation valve manifolds, and other systems to streamline and enhance your operations.
Fermentation tanks serve an integral role across multiple industries including food, beverages, pharmaceuticals, and biotechnology. Discover the diverse application scenarios for these tanks:
1. Beer Brewing Industry: A cornerstone of traditional and modern brewing practices.
1.1 Case Background: A testament to excellence in brewing technology.
• Customer: A prestigious and renowned brewery based in Germany, known for its dedication to quality.
• Products: A diverse array of beer products, each crafted to perfection.
• Scale: A robust production capacity reaching approximately 1 million liters of beer annually, showcasing their expansive capabilities.
1.2 Application Scenarios: Delve into the intricate processes that elevate beer to an art form.
Malt Processing: Expertly grind malt and seamlessly integrate it into hot water for saccharification, extracting a rich malt extract.
Fermentation: Post cooling, the malt extract receives yeast and is introduced to the fermentation tank where yeast masterfully converts sugars into alcohol and carbon dioxide, crafting the essence of beer.
Secondary Fermentation: Certain beer varieties undergo a secondary fermentation to enhance complexity and refine flavor profiles.
• Filtration: Following fermentation, clarity is achieved by meticulously removing yeast and solids through a sophisticated filtration system, resulting in pristine and clear beer.
• Filling: Gracefully pour the meticulously filtered beer into premium bottles or sturdy barrels, sealing them with precision to ensure flawless packaging.
• Storage and transportation: Preserve the excellence of finished products in state-of-the-art refrigerated warehouses, ensuring their pristine quality as they await transportation to distribution centers.
1.3 Fermentation tank equipment
Material: Crafted from robust stainless steel, this tank is corrosion-resistant and designed for effortless cleaning, ensuring longevity and hygiene.
• Capacity: An impressive 10,000 liters, designed for large-scale production needs.
• Temperature control: Features a sophisticated temperature control system to maintain an ideal, consistent environment during the entire fermentation process.
Mixing device: Includes an advanced mixer to facilitate the seamless distribution of yeast, ensuring uniform fermentation.
Exhaust system: Equipped with a precision exhaust valve, expertly releasing carbon dioxide to maintain optimal conditions.
Sampling port: Designed for effortless regular sampling and accurate testing of fermentation conditions, ensuring quality control.
2. Wine making industry
2.1 Case Background
• Customer: A renowned and prestigious wine estate in the heart of France, known for its excellence.
• Products: Exquisite Red Wine and crisp, refreshing White Wine, crafted with expertise.
• Scale: An impressive annual production of approximately 500,000 liters of world-class wine.
2.2 Application Scenarios
Grape processing: Meticulously remove stems and expertly crush harvested grapes to extract the purest grape juice.
Fermentation: Gently introduce grape juice into a state-of-the-art fermentation tank, where yeast works its magic, transforming sugar into delightful alcohol and effervescent carbon dioxide.
• Aging: Allow select wines to gracefully age in luxurious oak barrels, enhancing their rich, complex flavor profiles.
• Filtration: Upon completion of fermentation, carefully filter out yeast and solids to achieve a brilliantly clear wine.
• Filling: Elegantly fill the crystal-clear, filtered wine into bottles, sealing them securely to preserve their exquisite quality and taste.
• Storage and transportation: Store these fine wines in a meticulously maintained, constant-temperature wine cellar, as they await their journey to market shelves.
2.3 Fermentation tank equipment
• Material: Crafted from premium stainless steel or luxurious oak, catering to diverse production needs.
• Capacity: Generous 5,000 liters, tailored for medium-scale operations.
• Temperature control: Incorporates a cutting-edge temperature control system to maintain a perfect environment throughout fermentation.
Mixing device: Equipped with a sophisticated mixer that ensures even distribution of yeast for perfect fermentation.
Exhaust system: Features a precision-engineered exhaust valve that efficiently releases carbon dioxide.
Sampling port: Strategically designed for effortless regular sampling and precise testing of fermentation conditions.
3. Biopharmaceutical industry
3.1 Case Background
Client: An innovative biopharmaceutical company based in the United States, at the forefront of medical advancements.
• Product: High-efficacy recombinant protein drug, crafted with scientific expertise.
• Scale: A remarkable annual production capacity of approximately 100 kilograms of this vital recombinant protein.
3.2 Application Scenarios
• Strain cultivation: Inoculate genetically engineered strains into small-scale culture media, setting the stage for significant breakthroughs in preliminary cultivation.
• Scaling up cultivation: Transition these initially cultivated strains to a larger fermentation tank for extensive cultivation, meticulously controlling parameters to ensure the optimal growth environment.
• Harvesting: Upon completing fermentation, skillfully harvest the target protein using advanced techniques like centrifugation and filtration.
Purification: Expertly purify the harvested protein to remove impurities, achieving a high-purity target protein ideal for medical use.
• Filling: Fill the pristine, purified protein into sterile containers, sealing them meticulously for impeccable packaging.
• Storage and transportation: Securely store these vital biopharmaceutical products in cutting-edge refrigerated facilities as they await transportation to hospitals or pharmacies, ready to make an impact.
3.3 Fermentation Tank Equipment - Elevate your production line with our state-of-the-art fermentation tanks, designed for efficiency and durability.
Material: Crafted from premium stainless steel, our tanks boast unparalleled corrosion resistance and ease of cleaning, ensuring longevity and hygiene.
• Capacity: A robust 5000-liter capacity, engineered to meet large-scale fermentation demands with precision and reliability.
• Temperature Control: Our advanced temperature control system guarantees optimal thermal conditions, safeguarding your fermentation process with unwavering consistency.
• pH Control: Equipped with a cutting-edge pH control system, our tanks maintain a stable and ideal pH balance, crucial for successful fermentation.
• Dissolved Oxygen Control: Our tanks feature a sophisticated dissolved oxygen control system, ensuring the perfect oxygen levels for effective fermentation.
Mixing Device: Featuring a superior mixing device, our tanks ensure even distribution of bacterial strains, enhancing fermentation efficiency.
Exhaust System: Our tanks include an exhaust valve system designed to efficiently manage and release exhaust gases, maintaining a safe environment.
Sampling Port: Engineered for convenience, our sampling port allows for effortless, regular testing of fermentation conditions, ensuring optimal results.
4. Dairy Industry - Harness the power of our fermentation tanks to revolutionize your dairy production, elevating the quality and efficiency of your operations.
4.1 Case Background - Dive into our comprehensive case study to discover how our technology empowers leading dairy enterprises.
• Customer: A distinguished large-scale dairy company leading the industry with innovation and quality.
• Products: Specializing in exquisite yogurt and fermented milk, these products embody superior taste and nutritional value.
• Scale: Impressively, the company holds an annual production milestone of 10 million liters of high-quality fermented milk.
4.2 Application Scenarios - Explore diverse applications of our fermentation technology, tailored to enhance dairy processing excellence.
• Raw Material Processing: Begin with rigorous pre-treatment of fresh milk, incorporating standardization, homogenization, and meticulous sterilization.
Fermentation: Transitioning to our tanks, pre-treated milk undergoes fermentation where lactic acid bacteria work their magic, transforming lactose into lactic acid, resulting in perfectly solidified milk.
• Cooling: Post-fermentation, our technology ensures rapid cooling of milk to halt fermentation, preserving flavor and quality.
• Filling: Seamlessly transition to filling, where cooled milk is carefully bottled or cupped and securely sealed for optimal packaging.
• Storage and Transportation: Our comprehensive solution ensures finished products are stored in refrigerated warehouses, primed for market distribution.
4.3 Fermentation Tank Equipment - Our tanks are the backbone of innovative dairy processing, engineered for uncompromising quality and performance.
Material: Constructed with high-grade stainless steel, offering exceptional corrosion resistance and effortless cleaning for long-lasting use.
• Capacity: An impressive 10000-liter capacity, designed to accommodate substantial fermentation volumes with precision.
• Temperature Control: Our tanks feature an advanced temperature system, ensuring consistent and optimal fermentation conditions.
Mixing Device: Equipped with a high-efficiency mixer, our tanks ensure the even and thorough distribution of lactic acid bacteria.
Exhaust System: Includes an exhaust valve engineered to manage gas emissions efficiently, promoting a safe production environment.
Sampling Port: Our tanks come with a user-friendly sampling port, facilitating routine and precise testing of fermentation parameters.
Success Factors - Uncover the secrets to achieving unparalleled success in fermentation with our expertly curated solutions.
Equipment Selection: Tailor your production line with the ideal fermentation tank, matched to your scale and needs for maximum efficiency and stability.
• Strain Selection: Emphasize quality by selecting top-tier strains, ensuring a seamless and robust fermentation journey.
Process Optimization: Innovate with continuous process refinements, elevating both efficiency and product caliber.
Hygiene Management: Uphold stringent hygiene standards throughout production, assuring the safety and superiority of your products.
• Automation Level: Optimize your operations by choosing the right automation level, boosting efficiency and minimizing labor costs.
Your success is our mission. We trust that these fermentation tank applications will serve as invaluable resources. For more tailored support, contact us anytime!
Customization Process - Our bespoke yeast fermentation tank design process guarantees exceptional quality and performance tailored to your specifications.
Determine Requirements: Begin by defining your specific needs, including capacity, materials, and design features, to craft your ideal fermentation tanks. Firstly, articulate the exact requirements of your fermentation tanks, such as capacity ranging from 100L to 7000L, aligning with your production scale and budget constraints.
Material Selection: Choose the finest materials to ensure durability and optimal performance, tailored to your unique fermentation needs. The choice of material is paramount when customizing a fermentation tank. Stainless steel is highly favored for its superior corrosion resistance and ease of cleaning. To meet specific requirements, alternatives such as food-grade stainless steel can be chosen, ensuring that products adhere to stringent safety and hygiene standards.
Design features: Tailoring the fermentation tank to meet production process requirements often involves special designs. These may include sophisticated heating and cooling systems, advanced stirring devices, and convenient sampling ports. Such features are instrumental in substantially enhancing the efficiency of the fermentation process and boosting product quality.
Customized production: With requirements and design features specified, the path to customized production opens up. This involves selecting or crafting optimal heating and cooling systems while ensuring the seamless compatibility and safety of all components. Equally essential is considering ease of cleaning and maintenance for a streamlined operation.
Quality control: Rigorous quality control is indispensable throughout production, guaranteeing that all components and systems perform up to expectations. This encompasses material testing and thorough functional evaluations of systems, ensuring uncompromised quality at every stage.
After sales service: Post-customization, it is crucial to offer comprehensive after-sales services, including operation training and maintenance guidance. This ensures that users can operate the customized yeast fermentation tank both correctly and efficiently, maximizing its potential.
Following these meticulous steps, yeast fermentation tanks can be precisely customized in alignment with specific needs, significantly elevating production efficiency and quality.
Pre-sales services
After-sale service
1. Equipment warranty period: We offer a complimentary one-year warranty for all mechanical equipment. Should any non-human induced issues arise within this period, we commit to providing free repair or replacement services, ensuring peace of mind for our clients.
2. Maintenance and upkeep services: Our commitment extends to regular or ad-hoc maintenance and upkeep services, guaranteeing uninterrupted equipment operation. Additionally, we provide round-the-clock online technical support, ensuring expert assistance whenever needed.
3. Accessory supply: In the event of equipment damage or parts replacement, we assure prompt provision of genuine factory accessories, maintaining equipment integrity and performance.
4. Training services: To empower our customers in effectively operating and maintaining their equipment, we offer comprehensive training sessions focused on equipment operation and maintenance.
5. Installation and debugging: Our services encompass thorough equipment installation and debugging, ensuring precise setup and optimal operation from the start.
Company Profile
Our Service
Certificate
FAQ
1 ) Q: How can we visit your factory?
A: If you come from abroad, air to shanghai airport, then we can pick you up at airport.
2) Q: How do you ensure the quality of your products?
A: Our Company is a state owned enterprise with more than 16 years experience , strict operation policy is performed, advanced processing machines guarangtee the precision of all components, workers with operation license, parts get multiprocessing, transmission& electrical parts are of international famous brand. Series of test and inspection are done in the whole producing state.
3) Q: What payment methods your company accept?
A: We accept most of the payment methods , but mainly accept T/T, L/C at sight .
4) Q: How long is the warranty time for your products?
A: Our officially promised warranty time is 12 months after commissioning .
5) Q: I am new in this field,can you supply us turnkey services?
A: YES.We can supply all the system including Market Analysis/Product Analysis/Location Choice/Processing Flow Design/Equipment Layout Design/Building Design direction/Equipment mode selection/Equipment Manufacturing/Equipment Mounting/Equipment Debugging/Worker Training.
6) Q: What ' s the shipment terms and delivery time of your company?
A: Well, the delivery time depend on the quantity of your order. Usually is 20 days . For some customized machine 30 days is necessary.
7) Q: Can you supply OEM services?
A: Yes,we have our R&D team,and we have more than 400 workers with workshop area 75000 square meters.
8) Q: Do you give any Discount?
A: I will surely try my best to help you get those by the best price and good service at the same time.
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