| Customization: | Available |
|---|---|
| After-sales Service: | One year |
| Warranty: | One year |
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Industrial Fermentation Tank with Stirring for Dairy and Beverage Manufacturing
Our premium Fermentation Tank, sometimes referred to as a bioreactor, is a pivotal container employed across a myriad of industries, from brewing delightful beers and fine wines to the intricate realms of biotechnology, pharmaceuticals, and chemical processing. This innovative equipment is integral for nurturing the growth and metabolic processes of microorganisms, such as yeast and bacteria, or cells, like animal and plant cells, under meticulously controlled conditions. This controlled environment results in the production of a wide array of valuable products, including but not limited to alcohol, enzymes, antibiotics, biofuels, and even vaccines, showcasing its versatility and essential role in modern production.
Every Fermentation Tank is crafted with a keen focus on design, incorporating several crucial components that ensure exceptional performance and reliability:
1. Tank body: Our tanks provide a completely sealed environment, with capacities ranging from modest liters to expansive thousands of cubic meters. They are meticulously constructed from stainless steel, guaranteeing optimal sterility and corrosion resistance for enduring use.
2. Stirring system: This vital feature ensures homogeneity within the tank by mixing materials thoroughly, promoting the even distribution of essential nutrients, oxygen, or carbon dioxide, thereby facilitating robust microbial growth and optimal product formation. Our mixers come in diverse designs, including turbine and paddle types, tailored to meet specific application needs.
3. Temperature control system: Maintaining the perfect fermentation temperature is paramount for microorganism activity. Our tanks achieve this through advanced jacket heating or cooling coils, coupled with precision temperature control systems to ensure stability and efficiency throughout the process.
4. Ventilation and defoaming system: For those processes that require aerobic fermentation, our system provides sterile air or oxygen and efficiently manages the removal of carbon dioxide and other by-products. The incorporation of defoamers or specially designed tools effectively mitigates foam production, optimizing the fermentation process.
5. Sensors and control systems: Our state-of-the-art monitoring and control systems diligently track and regulate crucial parameters such as pH, dissolved oxygen (DO), temperature, and pressure. This ensures that conditions remain at their optimal state for maximum fermentation efficiency.
6. Sampling and feeding ports: Designed for convenience, these ports facilitate easy sampling and analysis throughout the fermentation process, allowing for the timely addition of nutrients and pH adjustment solutions as required.
7. Sterilization and cleaning system: Ensuring rigorous sterilization and cleaning before and after each use is critical to prevent contamination and guarantee uniformity across batches. Equipped with cutting-edge technology, our tanks integrate advanced monitoring and data acquisition systems, enabling remote monitoring and management to enhance both efficiency and product quality.
Tank configuration: Made from high-grade stainless steel SUS316/SUS304;
Incorporated with jacket temperature control and optimized diversion design for superior thermal management;
Interior surfaces are polished to an Ra≤0.6μm finish, and exterior surfaces feature either a polished or matte treatment for aesthetic appeal;
Equipped with a wide visual angle long-bar sight glass, and comprehensive connections for PH, DO, and temperature electrodes, offering real-time analytics;
The tank cover is thoughtfully designed with a flame inoculation port and a standby feeding port for versatile operations.
Stirring system:
Featuring a top-of-the-line mechanical stirring system with an aseptic mechanical seal, and powered by either a DC or AC motor for reliable and efficient operation;
Standard configuration includes a 2-layer flat vane along with optional high-efficiency defoaming, bending, and axial flow vanes for tailored solutions;
Digital speed control is available, allowing precise rotation speed adjustments for optimal process requirements.
Structure mode:
The floor type framework is designed for space efficiency and ease of operation, making it a practical choice for any industrial setup.
Ventilating system:
Our system offers deep ventilation through full stainless steel piping for long-lasting durability;
Equipped with a glass rotor flowmeter display, pressure gauge display, and manual valve flow adjustment for precise control;
Features a German Sartorius high-efficiency bacteria removing filter with a stainless shell, boasting a precision of 0.01μm, ensuring clean and safe air supply;
Requires external compressed air, furnished with a high-quality water removing pressure stabilizer for consistent and stable air provision throughout the process.
The mass flow controller is a versatile option designed to enable seamless automation of air flow management.
State-of-the-art Tank Pressure Management
The top exhaust port is fitted with a precise pointer pressure gauge for real-time display of tank pressure. It features a stainless steel valve operated manually for user-friendly control.
For optimal convenience, the system offers an optional imported pressure transmitter and automatic control valve, providing effortless and precise automatic tank pressure control.
Advanced Temperature Regulation
With online inspection capabilities, you can enjoy digital settings that allow seamless switching between automatic and manual control modes;
Equipped with a high-accuracy Pt-100 temperature probe;
Featuring electric heating and external cooling water systems for precise automatic temperature management.
Sophisticated PH Balance Control
Leverage online inspection with a 2-way peristaltic pump for automatic incremental acid or alkali solution feeding, ensuring accurate PH adjustment;
Utilizes a premium imported PH electrode capable of withstanding high-temperature steam disinfection.
Dissolved Oxygen (DO) Monitoring
Continuous online inspection, with options for a range of 0-100% or an extended 0-200%;
Incorporating an imported DO electrode, it withstands high-temperature steam disinfection for reliable performance;
Optional feature available: integrated control with rotational speed and ventilation for enhanced oxygen management.
Precision Feeding Control
The system's standard configuration includes a 1-way peristaltic pump for time-proportional incremental feeding, with real-time volume display and recording capabilities.
Innovative Defoaming Solution
Featuring a conducting type foam electrode, the system automatically alerts operators in the event of an abnormal foaming condition;
The standard setup includes a 1-way peristaltic pump for both automatic and manual incremental feeding of defoaming agents, with constant monitoring and recording of feeding volumes.
Comprehensive Control System
This advanced system utilizes a Siemens PLC controller and a vibrant true color touch screen, ensuring comprehensive functionality and stable operations.
Efficient Sterilization Mode
SIP mode available with manual control for safe sterilization processes.
Innovative Equipment Features
Equipped with SIP for safe, reliable operations;
Designed to eliminate any risk of driving leakage;
Features a wide-angle vertical sight glass for clear and easy observation;
Offers various reliable inoculation modes, including a standard configuration flame inoculation port, differential pressure inoculation port, and other customizable formats;
The floor-type tank is designed with a refined and aesthetically pleasing appearance;
Ensures easy operation, as well as simple assembly and disassembly;
Custom designs for products of special specifications are available upon request.
The installation and fine-tuning of fermentation tanks are critical in the realms of brewing, biotechnology, and industrial production. This process profoundly influences production efficiency and product quality. Below is an overview of the general installation and debugging process for fermentation tanks, which may vary depending on equipment model, production procedures, and safety standards: Preparation Before Installation
1. Site Selection and Basic Inspection: Ensure that the chosen installation site aligns with the factory layout plan, and that the ground is level, durable, and capable of supporting the weight of the fermentation tank. Once foundation construction is complete, a meticulous level and stability inspection is required.
2. Technical Data Review: Meticulously review the installation manual and technical drawings for the fermentation tank to fully understand the equipment's structure, dimensions, installation requirements, and safety regulations.
3. Accessories Inspection: Thoroughly count and verify the completeness of all accessories, including pipes, valves, sensors, mixers, etc., ensuring that each component is intact and undamaged.
Installation Process 1. Lifting in Place: Employ specialized lifting equipment to gently elevate the Industrial Fermentation Tank with Stirring for Dairy and Beverage Manufacturing to its designated location. Prioritize safety and ensure no collisions occur during this delicate process. 2. Masterful Horizontal Alignment: Utilize a precise spirit level to meticulously adjust the tank for perfect horizontal balance, an essential factor for uniform and superior fermentation. 3. Seamless Pipeline Integration: Execute the connection of inlet and outlet pipes, exhaust systems, and CIP (Clean-in-Place) pipelines in accordance with detailed design schematics, guaranteeing airtight and leak-free joints. 4. Precision Electrical and Instrument Setup: Install critical sensors such as thermometers, pressure gauges, pH meters, and dissolved oxygen electrodes along with essential electrical components like motors and controllers, ensuring flawless wiring and connectivity.
Debugging Stage: Fine-tune the system to perfection. 1. Empty Load Test: Initiate with a sterile or clean water circulation test to scrutinize the seamless operation of valves, pumps, mixers, and other vital equipment. Confirm the absence of leaks, blockages, or unusual sounds. 2. Comprehensive Sealing Inspection: Conduct thorough airtightness or water pressure tests on the tank and interfaces, ensuring impeccable sealing under working conditions. 3. Advanced Control System Debugging: Calibrate the automation control system, such as the PID controller, to precisely manage temperature, pH, dissolved oxygen, and other critical parameters as per process specifications. 4. Microbial Inoculation Test: Perform small-scale microbial inoculation tests, diligently monitoring growth patterns and product formation to validate the system's exceptional performance. 5. Rigorous Cleaning and Disinfection: After every experiment, engage in thorough cleaning and disinfection of the fermentation tank, preparing it immaculately for subsequent uses.
Safety and Maintenance: A Commitment to Excellence • Strict Compliance: Uphold safety production regulations and ensure personal protective equipment is worn throughout the installation and commissioning phases. Conduct regular maintenance, inspecting and replacing parts as needed to guarantee enduring, stable operation. These steps are general guidelines; always consult the specific equipment manufacturer's manual and adhere to local safety regulations during operation.
Technical Parameters: Key Insights
|
Model |
Diameter |
External diameter |
Height(mm) |
Insulation(δ) |
Jacket(δ) |
Diameter of inlet/outlet |
|
BYFG-500 |
φ500 |
800 |
2140 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-1 |
φ1000 |
1050 |
2380 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-1.5 |
φ1500 |
1180 |
2550 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-2 |
φ2000 |
1340 |
2760 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-2.5 |
φ2500 |
1420 |
2940 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-3 |
φ3000 |
1540 |
3050 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-4 |
φ4000 |
1650 |
3200 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-5 |
φ5000 |
1780 |
3250 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-6 |
φ6000 |
1900 |
3350 |
50 |
1.5 |
φ38/φ51 |
|
BYFG-8 |
φ8000 |
2100 |
3800 |
60 |
1.5 |
φ65/φ51 |
|
BYFG-10 |
φ10000 |
2300 |
4050 |
60 |
1.5 |
φ65/φ51 |
|
BYFG-12 |
φ12000 |
2520 |
4450 |
60 |
1.5 |
φ65/φ51 |
The process of customizing stainless steel fermentation tanks involves several meticulous steps and considerations, ensuring the final product's quality and performance align with specific requirements. Key customization steps and precautions include:
Material Selection: Setting the Foundation Stainless steel stands as the material of choice for fermentation tank fabrication due to its exemplary corrosion and high-temperature resistance. Popular grades like SUS304 and AISI316L offer varying levels of corrosion resistance and mechanical properties tailored to specific application needs.
Customized Size: Tailored Precision Customization of the fermentation tank's size, including diameter, height, and total volume, caters to specific production demands. This adaptability ensures tanks fit diverse production scales and space constraints seamlessly.
Design Function: Enhanced Efficiency Incorporating features like mixers, temperature sensors, and pressure relief valves, tailored to specific production processes, can significantly boost fermentation efficiency and product quality.
Connection Method: Secure Integration The fermentation tank's inlet and outlet typically connect to the pipeline system using specific methods, such as flange or threaded connections, ensuring smooth material and gas flow. Select the method that best suits process requirements.
Customized Appearance: Brand Alignment Customize the tank's appearance, including colors and logos, to align with specific brand images or factory environments, enhancing visual integration and brand identity.
Production and Testing: Uncompromising Standards Post-customization, the fermentation tank undergoes rigorous manufacturing processes-cutting, welding, polishing-culminating in pressure and leak tests to ensure safety and performance meet stringent pre-defined standards.
After-Sales Service: Ensuring Satisfaction Our commitment to excellence shines through with our all-encompassing installation guidance and technical support, ensuring your fermentation tank operates with steadfast stability. Furthermore, we offer comprehensive maintenance and repair services, designed to keep your equipment in peak condition throughout its use.
By meticulously following these steps, our tailored stainless steel fermentation tanks not only fulfill precise production requirements but also significantly enhance both efficiency and quality of the end product. Crucially, maintaining open and effective communication with suppliers is integral to the customization process, ensuring every specification is thoroughly understood and flawlessly executed.
Pre-Sales Services
After-Sale Service
1. Equipment Warranty Period: Enjoy peace of mind with our one-year complimentary warranty service covering all mechanical equipment. Should any issues arise that are not caused by human error, we will promptly provide repair or replacement services at no additional cost during the warranty period.
2. Maintenance and Upkeep Services: To ensure your equipment functions flawlessly, we offer both scheduled and unscheduled maintenance services, along with 24-hour online technical support to address your needs anytime.
3. Accessory Supply: We are committed to supplying genuine factory parts swiftly for any equipment damages or parts replacements needed, securing reliable operations.
4. Training Services: Empower your team with our comprehensive training on equipment operation and maintenance, ensuring maximum efficiency and longevity of your equipment.
5. Installation and Debugging: Our expert team will handle all equipment installation and debugging services, ensuring your equipment is set up correctly and ready for optimal performance.
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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