| Customization: | Available |
|---|---|
| After-sales Service: | Field installation, commissioning and training |
| Warranty: | 1 Year |
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New 50L-300L Full-Auto Fermentation Bioreactor Tank for Food & Beverage Processing Manufacturing Plant
Fermentation tank bioreactor is a widely used equipment in fields such as biotechnology, pharmaceuticals, food processing, and chemical engineering, mainly used for the cultivation and fermentation process of microorganisms, cells, or enzymes. These devices can provide well controlled environmental conditions to optimize the growth of organisms, the production of metabolites, or other biological transformation processes.
The following are some key features and components of a fermentation tank bioreactor: Key features:
1. Temperature control: Maintain a constant optimal growth temperature through a built-in heating or cooling system.
2. PH regulation: Automatically monitor and adjust the pH of the culture medium to adapt to the optimal growth conditions of microorganisms or cells.
3. Dissolved oxygen control: Ensure sufficient dissolved oxygen supply to microorganisms through stirring and ventilation (air or oxygen), and some advanced systems can also achieve bubble free oxygen supply.
4. Nutrient supply: Add nutrients or supplements as needed during the cultivation process to support the sustained growth or product synthesis of the organism.
5. Sterilization capability: Equipment is usually designed with sterilization interfaces to thoroughly disinfect before and after use, preventing contamination.
6. Online monitoring: equipped with sensors to monitor important parameters such as temperature, pH value, dissolved oxygen concentration, pressure, etc., and provide real-time feedback data.
Component:
1 Tank body: used to accommodate culture media, the material is usually corrosion-resistant and can withstand a certain amount of internal pressure.
2. Stirring system: including a stirrer and motor, used for mixing culture medium, increasing dissolved oxygen and ensuring temperature uniformity.
3. Ventilation system: Provides gas (usually air or pure oxygen) and may include filtration devices to prevent contamination.
4. Temperature control system: including heating or cooling jackets, heat exchangers, etc., used for precise temperature control.
5. Sensors and controllers: Monitor and adjust environmental parameters inside the tank, such as pH, DO (dissolved oxygen), temperature, etc.
6. Supplement and discharge port: convenient for adding nutrient solution or removing samples and products.
7. Sterilization interface: used for CIP (in situ cleaning) and SIP (in situ sterilization) operations to maintain a sterile environment.
The design and control strategies of fermentation tank bioreactors can vary according to different application requirements (such as small-scale laboratory bioreactors to industrial large-scale production), but the core goal is to efficiently and safely carry out the biological manufacturing process.
| 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.
The installation and debugging of a fermentation tank bioreactor usually follow the following steps:
Site selection and planning: • Determine the installation location of the fermentation tank, taking into account factors such as ground bearing capacity, ventilation, transportation convenience of raw materials and products, and safety distance Adjust the layout according to equipment specifications and terrain conditions to ensure sufficient space for operation and maintenance.
• Infrastructure: • Prepare basic materials such as concrete, construct the foundation according to the design drawings, and ensure that the foundation is strong and level After the foundation reaches sufficient strength, subsequent installation can be carried out.
• Tank installation: Place the fermentation tank on a pre prepared foundation and securely secure the tank with bolts to ensure stability and no shaking
Pipeline and accessory connections: • Connect inlet and outlet pipelines, gas (such as oxygen and carbon dioxide) supply pipelines, and ventilation systems to ensure that all connections are sealed and leak free Install monitoring equipment such as temperature sensors and pressure gauges, as well as auxiliary facilities such as stirring, ventilation, heating or cooling
Electrical and Control System
Installation: • Install electrical control cabinets, including motors, controllers, instruments, etc., to ensure correct circuit connections and compliance with safety standards Preliminary debugging of the electrical system to verify whether each component can respond to control signals normally.
• Inspection and debugging: • Conduct a comprehensive inspection of the fermentation tank to confirm that there are no damaged or missing parts, and check if the fasteners are secure Conduct a no-load trial run, check the operation of the mixing system, heating/cooling system, and ventilation system, and adjust them to the optimal state Test safety protection devices, such as pressure relief valves, emergency stop buttons, etc., to ensure their proper functioning.
• Cleaning and disinfection: Before first use, thoroughly clean and disinfect the interior of the fermentation tank to meet sterile production requirements Small scale trial operation: Conduct small-scale fermentation experiments, monitor various parameters during the fermentation process, such as pH value, temperature, dissolved oxygen, etc., and fine tune control strategies based on actual operating conditions.
• Final inspection before formal operation: • After confirming that all debugging is correct, recheck all connections and security measures to ensure everything is ready
Formal feeding operation: • Start formal fermentation production, closely monitor various parameters in the initial stage, and be ready to adjust at any time to cope with unexpected situations. During the entire installation and debugging process, the equipment manufacturer's instruction manual and safety regulations should be strictly followed, and professional technical personnel should be invited for on-site guidance if necessary.
Fermentation tanks have a wide range of applications in biotechnology and the food industry, mainly used for microbial cultivation, enzyme production, antibiotic preparation, organic acid production, alcohol and beer brewing, etc. Here are some typical application cases of fermentation tanks:
1. Antibiotic production
1.1 Case Background
•
Client: A pharmaceutical company
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Product: Penicillin
•
Capacity: Annual production of 100 tons of penicillin
1.2 Production Process
one
Strain cultivation: Cultivate penicillin producing strains such as Penicillium in small fermentation tanks.
two
Inoculation: Inoculate the cultured bacterial strains into a large fermentation tank.
three
Fermentation: Large scale fermentation is carried out under controlled conditions such as temperature, pH, and dissolved oxygen.
four
Extraction: After fermentation, penicillin is extracted by centrifugation, filtration, and other methods.
five
Refinement: Purification of extracted penicillin to remove impurities.
six
Drying: Dry purified penicillin into powder.
seven
Packaging: Pack the dried penicillin powder into finished products for sale.
1.3 Key equipment
•
Small fermentation tank: used for cultivating bacterial strains.
•
Large fermentation tank: used for large-scale fermentation.
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Centrifuge: used for extracting penicillin.
•
Filter: used to further remove impurities.
•
Refining equipment: used for the purification of penicillin.
•
Drying machine: used for drying penicillin.
•
Packaging machine: used for packaging finished products.
2. Beer brewing
2.1 Case Background
•
Customer: A certain brewery
•
Product: Craft Beer
•
Capacity: Annual production of 5000 tons of beer
2.2 Production Process
one
Malt processing: Sprouting, drying, and crushing barley to produce malt.
two
Saccharification: Mix malt with water, heat and saccharify to extract sugar from malt.
three
Boiling: Boil the saccharified wort and add hops.
four
Cooling: Cool the boiled wort to the appropriate fermentation temperature.
five
Fermentation: Inoculate the cooled wort with yeast and place it in a fermentation tank for fermentation.
six
Post fermentation: After fermentation, post fermentation is carried out to make the beer more mature.
seven
Filtration: Removing solid impurities from beer through filtration.
eight
Filling: Fill filtered beer into bottles or barrels.
nine
Packaging: Packaging the filled beer into finished products ready for sale.
2.3 Key Equipment
•
Saccharification pot: used for saccharification of malt.
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Boiling pot: used for boiling wort.
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Cooler: Used for cooling wort.
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Fermentation tank: used for fermenting beer.
•
Post fermentation tank: used for post fermentation of beer.
•
Filter: Used to remove solid impurities from beer.
•
Filling machine: used for filling beer.
•
Packaging machine: used for packaging finished products.
3. Alcohol production
3.1 Case Background
•
Customer: A certain alcohol factory
•
Product: Edible alcohol
•
Capacity: Annual production of 2000 tons of edible alcohol
3.2 Production Process
one
Raw material preparation: Select suitable raw materials such as corn, sugarcane, etc.
two
Preprocessing: Grind and steam the raw materials to prepare fermented mash.
three
Saccharification: Saccharification of fermented mash to convert it into fermentable sugar.
four
Fermentation: Inoculate the saccharified mash with yeast and place it in a fermentation tank for fermentation.
five
Distillation: After fermentation, alcohol is extracted by distillation.
six
Refining: Refining the extracted alcohol to remove impurities.
seven
Filling: Fill the refined alcohol into a container.
eight
Packaging: Packaging the filled alcohol into finished products ready for sale.
3.3 Key Equipment
•
Crusher: Used for crushing raw materials.
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Steaming pot: used for steaming and cooking raw materials.
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Saccharification pot: used for saccharification of fermented liquor.
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Fermentation tank: used for fermenting fermented mash.
•
Distillation tower: used for the distillation of alcohol.
•
Refining equipment: used for refining alcohol.
•
Filling machine: used for filling alcohol.
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Packaging machine: used for packaging finished products.
Success factors
•
Strain selection: Choose strains with high yield and strong tolerance.
•
Process control: Accurately control fermentation conditions such as temperature, pH value, dissolved oxygen, etc.
•
Equipment maintenance: Regularly maintain and repair equipment to ensure stable production.
•
Quality control: Establish a strict quality control system to ensure product quality.
•
Environmental protection: Take measures to reduce wastewater and exhaust emissions and protect the environment.
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.
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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