Blending Paddle Yogurt Fermentation Tank 500L to 3000L Beverage Dairy Factory Manufacturing Plant
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.
Use: Usually used for bacterium seeding cultivating, which is used to make zymogen for yogurt.
The fermentation tank is used for mechanical blending and fermentation if material. The equipment adopts internal recycling mode and blending paddle to distribute and break up bubbles. Therefore, high speed of oxygen solution and good quality of blending are achieved. Tank body is made of SUS304 or SUS316L imported stainless steel, and automatic spraying and cleaning nozzle in the tank to ensure producing procedure comply with GMP requirements.
Use of fermentation tank: For mixing of all kinds of materials in dairy industry.
| Model |
Diameter |
External diameter |
Height ( mm ) |
PU Insulation ( δ ) |
Jacket ( δ ) |
Diameter of inlet/outlet |
| BYDG-500 |
φ500 |
800 |
2140 |
50 |
1.5 |
φ38 |
| BYDG-1 |
φ1000 |
1050 |
2380 |
50 |
1.5 |
φ38 |
| BYDG-1.5 |
φ1500 |
1180 |
2550 |
50 |
1.5 |
φ38 |
| BYDG-2 |
φ2000 |
1340 |
2760 |
50 |
1.5 |
φ38 |
| BYDG-2.5 |
φ2500 |
1420 |
2940 |
50 |
1.5 |
φ38 |
| BYDG-3 |
φ3000 |
1540 |
3050 |
50 |
1.5 |
φ38 |
| BYDG-4 |
φ4000 |
1650 |
3200 |
50 |
1.5 |
φ38 |
| BYDG-5 |
φ5000 |
1780 |
3250 |
50 |
1.5 |
φ38 |
| BYDG-6 |
φ6000 |
1900 |
3350 |
50 |
1.5 |
φ38 |
| BYDG-8 |
φ8000 |
2100 |
3800 |
60 |
1.5 |
φ65 |
| BYDG-10 |
φ10000 |
2300 |
4050 |
60 |
1.5 |
φ65 |
| BYDG-12 |
φ12000 |
2520 |
4450 |
60 |
1.5 |
φ65 |
Installing and debugging fermentation tanks is a crucial step in brewing, biotechnology, and related industrial production, which directly affects production efficiency and product quality. The following is a general process for installing and debugging fermentation tanks. The specific operations may vary depending on the equipment model, production process, and safety standards: preparation before installation
1.
Site selection and basic inspection: Ensure that the installation location conforms to the factory layout plan, the ground is flat and sturdy, and can bear the weight of the fermentation tank. After the completion of the foundation construction, a level and stability inspection is required.
2.
Technical data review: Carefully read the installation manual and technical drawings of the fermentation tank, understand the structure, dimensions, installation requirements, and safety regulations of the equipment.
3.
Accessories inspection: Count and check if all accessories are complete, including pipes, valves, sensors, mixers, etc., to ensure no damage.
Installation process 1. Lifting in place: Use appropriate lifting equipment to smoothly lift the fermentation tank to the predetermined position, paying attention to safety and avoiding collisions during the process. 2. Horizontal adjustment: Use a spirit level to adjust the fermentation tank horizontally, ensuring the absolute level of the tank body, which is crucial for even fermentation. 3. Pipeline connection: Connect the inlet and outlet pipes, exhaust pipes, CIP (on-site cleaning) pipelines, etc. according to the design drawings, ensuring that all connections are sealed and leak free. 4. Electrical and instrument installation: Install sensors such as thermometers, pressure gauges, pH meters, dissolved oxygen electrodes, as well as electrical equipment such as motors and controllers, and make wiring connections.
Debugging stage 1. Empty load test: First, conduct a circulation test of sterile water or clean water, check the operation of various valves, pumps, mixers, and other equipment, and confirm that there are no leaks, blockages, or abnormal noises. 2. Sealing inspection: Conduct an airtightness or water pressure test on the tank and its interfaces to ensure that there is no leakage under working pressure. 3. Control system debugging: According to the process requirements, set and debug the automation control system (such as PID controller) to ensure accurate control of temperature, pH value, dissolved oxygen and other parameters. 4. Microbial inoculation test: Conduct small-scale microbial inoculation tests, monitor growth curves and product formation, and verify the performance of the entire system. 5. Cleaning and disinfection: After each experiment, thoroughly clean and disinfect the fermentation tank according to the regulations to prepare for the next use.
Safety and Maintenance • Strictly adhere to safety production regulations and wear personal protective equipment throughout the entire installation and commissioning process Regularly maintain the equipment, inspect and replace vulnerable parts to ensure long-term stable operation. Please note that the above steps are general guidelines, and it is important to refer to the equipment manufacturer's specific instruction manual and local safety regulations during actual operation.
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
•
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.
•
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.
•
Boiling pot: used for boiling wort.
•
Cooler: Used for cooling wort.
•
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.
•
Steaming pot: used for steaming and cooking raw materials.
•
Saccharification pot: used for saccharification of fermented liquor.
•
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.
•
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.
The core elements and design details of a customized Yogurt Fermentation Tank include:
1.
Capacity and Scale: Determine the capacity of the fermentation tank based on your production needs, and consider future scalability by choosing an expandable design.
2.
Material: Made of corrosion-resistant, food grade 304 or 316L stainless steel, with an additional polyurethane insulation layer to ensure safety and insulation effect.
3.
Temperature control: Equipped with precise temperature control system (such as PID controller) and heating/cooling mechanism, maintain the ideal fermentation temperature of 38 ° C~45 ° C, and ensure small temperature difference inside the tank.
4.
Stirring and Mixing: Choose a mixer type that is suitable for yogurt viscosity and has adjustable speed function to promote uniform fermentation.
5.
Cleaning and disinfection: Integrated CIP/SIP system ensures that the inside and outside of the tank are easy to clean and disinfect, meeting hygiene standards.
6.
Safety and Monitoring: Equipped with pressure safety valves, leak detection systems, and automated control systems such as PLCs to enhance safety and monitoring capabilities.
7.
Regulations and Environmental Protection: Ensure that the design complies with food safety standards (ISO, HACCP, etc.) and environmental requirements.
8.
Personalized customization: Based on the actual production process, design interfaces, accessories, and appearance to enhance user convenience and corporate image.
Next, we suggest that you:
• Clarify requirement details: Based on the above points, plan your specific requirement parameters in detail.
Consult us for customized solutions and quotes.
• Evaluation and selection: Compare the cost-effectiveness, technical support, and after-sales service of different solutions, and make decisions. In this way, you can customize the most suitable yogurt fermentation tank solution based on actual production conditions.
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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