500L to 2000L Bio-Fermentation Reactor Tank for Processing Line 1000L Option Available
Fermentation tank, also known as fermentation tank or bioreactor, is a type of container equipment widely used in industries such as brewing (such as beer, wine), food processing, biotechnology, pharmaceuticals, and chemical industry. Its main function is to support the growth and metabolic processes of microorganisms (such as yeast, bacteria) or cells (such as animal cells, plant cells) under controlled conditions, in order to produce specific products such as alcohol, enzymes, antibiotics, biofuels, vaccines, etc.
The design of a fermentation tank usually includes the following key parts:
1.
Tank body: Provides a closed environment, with sizes ranging from a few liters to thousands of cubic meters, typically made of stainless steel to ensure sterility and corrosion resistance.
2.
Stirring system: used to mix materials inside the tank, ensuring uniform distribution of nutrients, oxygen (or carbon dioxide), and promoting microbial growth and product formation. There are various designs for mixers, including turbine and paddle types.
3.
Temperature control system: Maintaining an appropriate fermentation temperature is crucial for the activity of microorganisms. This is usually achieved through jacket heating or cooling coils and temperature control systems.
4.
Ventilation and defoaming system: For aerobic fermentation processes, provide sterile air or oxygen and effectively eliminate the generated carbon dioxide and other gases. At the same time, reduce foam in the fermentation process through defoamer or specially designed defoamer.
5.
Sensors and control systems: Monitor and control various parameters during the fermentation process, such as pH value, dissolved oxygen (DO), temperature, pressure, etc., to ensure that the fermentation conditions are stable in the optimal state.
6.
Sampling and feeding ports: facilitate sampling and analysis during the fermentation process, as well as adding nutrients, acid-base adjustment solutions, etc. as needed.
7.
Sterilization and cleaning system: Thoroughly sterilize and clean the fermentation tank before and after each use to prevent contamination and maintain consistency between batches.
Modern fermentation technology is highly automated, and many fermentation tanks are integrated with advanced monitoring and data acquisition systems (SCADA), which can remotely monitor and manage the fermentation process, improve 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:
Based on the ASME clean equipment standard to design and manufacture;complying with the requirements of Pressure Vessel at the same time;
(2)Inner surface treatment
Mechanical polishing Ra‹0.4μm,and then performing the mirror process;
(3)Outer surface treatment
Mechanical polishing Ra‹0.6μm,and then performing the matting process;
(4)No blind coner treatment
The inner welding line and the inner surface being polished,and structure components adopting the full length welding,and then polishing,inner coil pipe using the stress eliminating structure;
(5)Fastener structure
All fasteners using the bolt stud balancing double acorn nuts,PTFE materia as gasket seal;
(6)Mechanical seal
Using the washable,sterilized collection plate equipped mechanical seal fixed and moving ring friction sleeve to ensure the friction debris not falling into the tank;
sealed pattern:dry or wet type,single end face or dual end face;
(7)Heat exchange type
Full Jacket,dimple jacket,semicircle-pipe jacket,inner coil,inner tubulation;
• Piping system features:
(1) Processing piping
Adopting ASME sanitary grade internal and external polished cleanig pipe.It is weld automatically with argon gas,inspected by endoscope.
(2)Valves
The valves connected with tanks all adopting double membrane combination
diaphragm valve;all steam and compressed air valve are both using stop valves and sanitary ball valves.
(3)Double membrane diaphragm type tank bottom valve ,sterilizing at the product outlet before sampling;
(4)Online sterilization
Adopting the clean and saturated steam filtered by 0.5μm titanium rod filter;
(5)Sampling method
Adopting the diaphragm type aseptic sampling valve,doing online sterilization before sampling and take aseptic sample;
(6)Subcultivation
The pipe can be sterilized during the whole progress,installing the thermometer to sterilization detection;
(7)Inoculation method
Flame ring type,different pressure type;
(8)Feeding mode
Peristaltic pump,measuring cup,etc.
(9)Multi-stage culture expanding system subcultivation
Subcultivation distributor to do the multitubes distribution subcultivation valve manifolds subcultivation,etc.
Fermentation tanks are widely used in various industries such as food, beverages, pharmaceuticals, and biotechnology. Here are several specific application cases of fermentation tanks:
1. Beer brewing industry
1.1 Case Background
• Customer: A well-known brewery in Germany
• Products: Various types of beer
• Scale: Annual production of approximately 1 million liters of beer
1.2 Application Scenarios
Malt processing: Grind the malt and add it to hot water for saccharification to extract malt extract.
Fermentation: After cooling the malt extract, yeast is added and sent to the fermentation tank for fermentation. During the fermentation process, yeast converts sugar into alcohol and carbon dioxide.
Secondary fermentation: Some beers require secondary fermentation to further enhance the complexity and flavor of the beer.
• Filtration: After fermentation is complete, yeast and other solid substances are removed through a filtration system to obtain clear beer.
• Filling: Fill the filtered beer into bottles or barrels and seal them for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to distribution centers.
1.3 Fermentation tank equipment
Material: Stainless steel, corrosion-resistant, easy to clean
• Capacity: 10000 liters
• Temperature control: Equipped with a temperature control system to ensure constant temperature during the fermentation process
Mixing device: equipped with a mixer to promote uniform distribution of yeast
Exhaust system: equipped with an exhaust valve to release carbon dioxide gas
Sampling port: convenient for regular sampling and testing of fermentation conditions
2. Wine making industry
2.1 Case Background
• Customer: A famous wine estate in France
• Products: Red Wine, White Wine
• Scale: Annual production of approximately 500000 liters of wine
2.2 Application Scenarios
Grape processing: Remove the stems and crush the harvested grapes to extract grape juice.
Fermentation: Put grape juice into a fermentation tank and add yeast for fermentation. During the fermentation process, yeast converts sugar into alcohol and carbon dioxide.
• Aging: Some wines need to be aged in oak barrels to enhance their flavor.
• Filtration: After fermentation is complete, yeast and other solid substances are removed through a filtration system to obtain clear wine.
• Filling: Fill the filtered wine into a bottle and seal it for packaging.
• Storage and transportation: Store finished products in a constant temperature wine cellar and wait for transportation to the market.
2.3 Fermentation tank equipment
• Material: Stainless steel or oak
• Capacity: 5000 liters
• Temperature control: Equipped with a temperature control system to ensure constant temperature during the fermentation process
Mixing device: equipped with a mixer to promote uniform distribution of yeast
Exhaust system: equipped with an exhaust valve to release carbon dioxide gas
Sampling port: convenient for regular sampling and testing of fermentation conditions
3. Biopharmaceutical industry
3.1 Case Background
Client: A biopharmaceutical company in the United States
• Product: Recombinant protein drug
• Scale: Annual production of approximately 100 kilograms of recombinant protein
3.2 Application Scenarios
• Strain cultivation: Inoculate engineered strains containing target genes into small-scale culture media for preliminary cultivation.
• Scaling up cultivation: Transfer the initially cultivated strains to a fermentation tank for large-scale cultivation. During the cultivation process, the optimal growth environment for the bacterial strain is ensured by controlling parameters such as temperature, pH value, and dissolved oxygen.
• Harvesting: After fermentation is completed, the target protein is harvested through methods such as centrifugation and filtration.
Purification: Purify the harvested protein to remove impurities and obtain high-purity target protein.
• Filling: Fill the purified protein into a sterile container and seal it for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to hospitals or pharmacies.
3.3 Fermentation tank equipment
Material: Stainless steel, corrosion-resistant, easy to clean
• Capacity: 5000 liters
• Temperature control: Equipped with a temperature control system to ensure constant temperature during the fermentation process
• pH control: equipped with a pH control system to ensure stable pH value during fermentation process
• Dissolved oxygen control: equipped with a dissolved oxygen control system to ensure appropriate dissolved oxygen concentration during fermentation process
Mixing device: equipped with a mixer to promote uniform distribution of bacterial strains
Exhaust system: equipped with an exhaust valve to discharge exhaust gas
Sampling port: convenient for regular sampling and testing of fermentation conditions
4. Dairy industry
4.1 Case Background
• Customer: A large dairy product company
• Products: Yogurt, Fermented Milk
• Scale: Annual production of approximately 10 million liters of fermented milk
4.2 Application Scenarios
• Raw material processing: Pre treat fresh milk, such as standardization, homogenization, sterilization, etc.
Fermentation: Transfer the pre treated milk into a fermentation tank and add lactic acid bacteria for fermentation. During the fermentation process, lactic acid bacteria convert lactose into lactic acid, causing milk to solidify.
• Cooling: After fermentation is complete, cool the fermented milk to a suitable temperature to prevent excessive fermentation.
• Filling: Fill the cooled fermented milk into a cup or bottle and seal it for packaging.
• Storage and transportation: Store finished products in refrigerated warehouses and wait for transportation to the market.
4.3 Fermentation tank equipment
Material: Stainless steel, corrosion-resistant, easy to clean
• Capacity: 10000 liters
• Temperature control: Equipped with a temperature control system to ensure constant temperature during the fermentation process
Mixing device: equipped with a mixer to promote uniform distribution of lactic acid bacteria
Exhaust system: equipped with an exhaust valve to discharge exhaust gas
Sampling port: convenient for regular sampling and testing of fermentation conditions
Success factors
Equipment selection: Select suitable fermentation tank equipment based on production scale and demand to ensure efficient and stable production.
• Strain selection: Select high-quality strains to ensure a smooth fermentation process.
Process optimization: Continuously optimizing fermentation processes to improve production efficiency and product quality.
Hygiene management: Strictly control the hygiene conditions during the production process to ensure product quality and safety.
• Automation level: Select the appropriate level of automation based on the production scale to improve production efficiency and reduce labor costs.
I hope these application cases of fermentation tanks can provide you with reference and assistance. If you have more specific needs or questions, please feel free to let me know at any time!
The process of customizing yeast fermentation tanks involves multiple steps to ensure that the quality and performance of the final product meet specific requirements. Here are some key steps and considerations to guide how to customize yeast fermentation tanks:
Determine requirements: Firstly, it is necessary to clarify the specific requirements for customizing fermentation tanks, including capacity, material, design features, etc. For example, the capacity of fermentation tanks can range from 100L to 7000L, and the appropriate capacity can be selected based on production scale and budget.
Material selection: The material of the fermentation tank is also an important factor to consider when customizing. Stainless steel is a common material choice due to its excellent corrosion resistance and easy cleaning properties. In addition, other materials such as food grade stainless steel can be selected according to specific needs to ensure the safety and hygiene standards of the product.
Design features: According to the production process requirements, special designs may be needed for the fermentation tank, such as heating and cooling systems, stirring devices, sampling ports, etc. These design features can greatly improve the efficiency of the fermentation process and product quality.
Customized production: Once the requirements and design features are determined, customized production can begin. This includes selecting or designing appropriate heating and cooling systems, as well as ensuring compatibility and safety of all components and systems. Meanwhile, it is also necessary to consider how to facilitate cleaning and maintenance.
Quality control: Strict quality control is required during the production process to ensure that the performance of all components and systems meets expectations. This may include testing of materials, functional testing of systems, etc.
After sales service: After customization is completed, necessary after-sales services such as operation training, maintenance guidance, etc. need to be provided to ensure that users can use the customized yeast fermentation tank correctly and efficiently.
Through the above steps, suitable yeast fermentation tanks can be customized according to specific needs, thereby improving production efficiency and quality.
Pre sales services
After-sale service
1. Equipment warranty period: We provide a one-year free warranty service for mechanical equipment. If any non-human caused problems occur during the warranty period, we will provide free repair or replacement services.
2. Maintenance and upkeep services: We provide regular or irregular equipment maintenance and upkeep services to ensure the normal operation of the equipment. We will provide 24-hour online technical support services.
3. Accessory supply: We guarantee to provide original factory accessories in a timely manner in case of equipment damage or replacement of parts.
4. Training services: In order to enable customers to effectively operate and maintain equipment, we will provide equipment operation and maintenance training.
5. Installation and debugging: We will provide equipment installation and debugging services to ensure that the equipment is installed correctly and can operate normally.
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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