Stainless steel bioreactor fermenter bioreactor bioreactor tank
A bioreactor is a complex engineering technology device designed to simulate biological processes within or in nature, in order to promote and control the growth, reproduction, or metabolic activities of organisms (such as microorganisms, cells, tissues, or organs) outside the body. Bioreactors are widely used in various fields such as biotechnology, pharmaceuticals, environmental protection, food, and agriculture. Specific applications include but are not limited to:
1. Microbial fermentation: In the pharmaceutical industry, bioreactors are often used for large-scale microbial fermentation to produce antibiotics, amino acids, organic acids, and other biological products.
2. Cell culture: In the field of biomedicine, bioreactors are used to cultivate animal or human cells, such as producing recombinant protein drugs such as insulin and antibody drugs, or conducting stem cell amplification and tissue engineering research.
3. Remediation of contaminated soil: Elevated reactors and other equipment can be used to treat soil contaminated with organic matter, accelerating the biodegradation of pollutants by optimizing the growth conditions of microbial communities.
4. Genetically modified bioreactors: This refers to the use of genetic engineering technology to modify animals (such as sheep, cows) or plants to produce specific drug proteins. Such organisms themselves are like natural bioreactors that can produce the drug components needed by humans in their milk or tissues.
5. Immobilized enzyme or cell reactor: By immobilizing the enzyme or cell onto a carrier through immobilization technology, a stable biocatalyst is formed to achieve continuous and efficient catalytic reactions.
The design of bioreactors requires consideration of multiple key factors, including temperature, pH value, dissolved oxygen, nutrient supply, shear stress, product inhibition, mixing efficiency, etc., and is typically equipped with precision monitoring and control systems to adjust and optimize operating conditions in real-time, ensuring the effectiveness and safety of biological processes.
Nominal volume: 10L,15L ,30L,50L,70L,100L,150L,200L
Liquid loading coefficient: ≥70%
Tank configuration :
Stainless steel SUS316/SUS304;
Jacket temperature control,optimized diversion design;
Interior surface polishing ,Ra≤0.6μm; exterior surface polishing or matte treatment;
Wide visual angle long-bar sight glass, PH electrode ,DO electrode, temperature electrode with complete connections;
The tank cover is equipped with the flame inoculation port and standby feeding port.
Stirring system
Top mechanical stirring system , aseptic mechanical seal system , DC stirring motor or AC motor;
Standard configuration 2-layer flat vane , first-class high-efficiency defoaming vane , bending vane and axial flow vane are optional;
Speed control available , digital setting of rotation speed control.
Structure mode
Floor type framework , space saving , convenient operation.
Ventilating system
Deep ventilating ,full stainless steel pipe;
Liquid deep ventilating;
Glass rotor flow-meter display , pressure gauge display , manual valve flow adjustment;
Equipped with German Sartorius high-efficiency bacteria removing filter of stainless shell with a precision of 0.01μm;
External compressed air is required , equipped with high quality water removing pressure stabilizer for continuous and stable air supply;
The mass flow controller is optional to automatically control air flow.
Tank pressure control
The top exhaust port is equipped with the pointer pressure gauge to display the tank pressure. The stainless steel valve adopts manual control.
The optional imported pressure transmitter and automatic control valve realize automatic control of tank pressure
Temperature control
Online inspection , digital setting , free switching between automatic and manual control;
Pt-100 temperature probe;
Electric heating temperature control and external cooling water for automatic temperature control.
PH control
Online inspection , 2-way peristaltic pump automatic incremental feeding of acid or alkali solution for adjustment;
Imported PH electrode realizes high temperature steam disinfection.
Dissolved oxygen(DO)
Online inspection , with a range of 0-100% or 0-200%;
Imported DO electrode realizes high temperature steam disinfection;
Optional , linked control with rotation speed and ventilation.
Feeding control
Standard configuration 1-way peristaltic pump time proportional incremental feeding , with the volume of incremental feeding being displayed and recorded.
Defoaming mode
Conducting type foam electrode , automatic alarming in case of abnormal foam situation;
Standard configuration 1-way peristaltic pump automatic/manual incremental feeding of defoaming agent , with the volume of incremental feeding being displayed and recorded.
Control system
Siemens PLC controller true color touch screen with complete functions and stable running .
Sterilizing mode
SIP , manual control
Equipment features
SIP , safety and reliable ;
Without driving leakage risk;
Wide visual angle vertical sight glass with clear observation;
Various reliable inoculation modes (standard configuration flame inoculation port,differential pressure inoculation port and other various optional forma);
Floor type tank with beautiful appearance;
Easy operation , assembly and disassembly;
Products of special specifications can be made to order;
Optional
1.Multi-way feeding
2.Automatic sterilization
3.Weighing of fed materials
4.Tank body weighing
5.Rich oxygen bypass
6.ORP online inspection
7.Air flow automatic inspection and control
8.Tail gas O2,CO2 content online inspection
9.Methanol (alcohol) content online inspection
Bioreactor technology involves multiple core technologies and related supporting systems. The following are some key technical points:
1. Material transfer and mixing technology: • Mixing system: Ensure the uniform distribution of microorganisms, cells, or biomass in the container, usually using a stirrer or gas disperser to achieve mixing, to ensure the uniform distribution of nutrients, oxygen, and products in the reaction medium Fluid dynamics design: Reasonably design the fluid flow mode inside the reactor, such as axial mixing, radial mixing, or composite mixing methods, to ensure good mass transfer efficiency.
2. Temperature control technology: • Temperature sensors and temperature control systems: Maintain a constant or programmed temperature inside the reactor, which is crucial for the growth and metabolism of microorganisms or cells.
3. pH regulation technology: • Online pH monitoring and regulation: The by-products generated during the biological reaction process may change the pH value of the system, so real-time monitoring and automatic addition of alkali or acid are required to maintain the ideal pH range.
4. Dissolved oxygen control technology: • Gas diffusion system: Oxygen is supplied to the liquid through methods such as microporous aeration and propeller stirring, ensuring that microorganisms or cells have sufficient dissolved oxygen for respiratory metabolism.
5. Nutrient supplementation and waste discharge technology: • Continuous flow or batch feed system: Add fresh culture medium or remove waste culture medium to the reactor as needed to maintain optimal nutrient balance and product accumulation.
6. Automation control and monitoring technology: • Data acquisition and control system: Integrate various sensor data, such as temperature, pH, dissolved oxygen, CO2 content, biomass, etc., achieve fine management through automation software, and adjust operating parameters in real time.
7. Fixed Biotechnology: • Utilizing immobilized enzymes or immobilized cell technology to immobilize microorganisms or enzymes on a carrier, improving the stability of biocatalysts and facilitating continuous operation.
8. Safety and Health Technology: • Design a closed system that meets GMP requirements, use sterile operation technology to prevent contamination, and have a complete cleaning and disinfection (CIP/SIP) process. 9. New type of bioreactor design: such as multi-stage bioreactors, membrane bioreactors (MBRs), airlift reactors, photobioreactors, etc., to design optimized reactor structures for different biological process requirements.
In summary, bioreactor technology covers multiple disciplines such as biological process engineering, fluid dynamics, mass transfer theory, microbial physiology, and automation control, striving to achieve efficient, stable, and controllable biological transformation processes. With the advancement of technology, new bioreactor technologies are constantly emerging to meet the more complex needs of biological manufacturing and environmental protection.
Bioreactors can produce a wide range of biological products, mainly derived from the growth, metabolism, or expression activities of microorganisms, cells, or biomolecules.
The following are some final products that bioreactors may produce:
1. Medical products: • Drug proteins: therapeutic protein drugs such as insulin, interferon, growth hormone, monoclonal antibodies, etc Vaccines: such as viral particle vaccines, recombinant subunit vaccines, etc Disease diagnostic reagents, such as enzyme labeled antibodies in enzyme-linked immunosorbent assay (ELISA).
2. Bioenergy: • Biofuels: Liquid fuels obtained through microbial fermentation, such as ethanol and butanol Biohydrogen: Some microorganisms can produce hydrogen gas under specific conditions.
3. Food additives and nutrients: • Enzyme preparations: Enzymes widely used in food processing and beverage production, such as amylase and lipase Functional food ingredients: such as probiotics, dietary fiber, functional polysaccharides, etc.
4. Chemical raw materials: • Biobased chemicals: such as precursors of bioplastics, biobased lubricants, biosurfactants, etc Fermented products: organic acids and alcohol compounds such as lactic acid, citric acid, acetone butanol, etc.
5. Environmental governance: • Bioremediation agents: Microbial agents used for wastewater treatment or soil remediation Biological desulfurizer: Utilizing microorganisms to remove sulfides from harmful gases.
6. Scientific research applications: Various molecular biology tools such as recombinant proteins and RNA used in basic scientific research.
In summary, bioreactors play a crucial role in the modern biotechnology industry, optimizing biological processes to achieve large-scale production and commercial application of various biological products.
The installation and debugging of a bioreactor is a meticulous and professional task, covering multiple steps and technical points. Below is an overview of the main steps of bioreactor installation and debugging:
Installation phase
1. On site preparation: • Ensure that the installation area is clean, level, dust-free, and complies with biosafety and electrical safety regulations Arrange appropriate support foundations or frames according to the weight and size of the equipment.
2. Equipment positioning: Use appropriate lifting tools and personnel, and correctly handle and place the main body and ancillary equipment of the bioreactor according to the instructions, such as controllers, power equipment, pipelines, and instruments.
3. Pipeline connection: Install inlet and outlet pipelines, circulation pipelines, ventilation pipes, cleaning liquid pipes, sewage pipes, etc., and ensure that all connections are sealed reliably to avoid leakage.
4. Electrical installation: Professional electricians shall complete the installation of power cables, signal cables, control panels and other electrical parts according to the electrical drawings, ensuring good grounding and stable installation of electrical components.
5. Instrument configuration: Install various sensors such as temperature probes, pH electrodes, dissolved oxygen meters, pressure gauges, etc., and calibrate them to normal working conditions.
6. Control system integration: • Integrate the reactor with its supporting automatic control system (such as PLC or DCS), set and debug various control parameters.
Debugging phase
1. Preliminary startup: • Turn on the power, conduct a comprehensive inspection of the control system, confirm that each unit is functioning properly, and execute the preset self-test program.
2. No load operation: Start the stirring system, temperature control system, ventilation system, etc. of the reactor without biological load, conduct no-load debugging, and test the equipment performance and system stability.
3. Simulated operation: • Use simulated solutions instead of actual biological media for trial operation, test the operation status of the equipment under conditions close to actual operating conditions, and adjust and optimize control strategies.
4. Introduction of Bioburden: Based on experimental or production plans, introduce microbial or cellular bioburden and gradually adjust it to process conditions suitable for biological growth and metabolism.
5. Process parameter optimization: Based on the biological reaction process, dynamically adjust parameters such as temperature, pH value, dissolved oxygen, and nutrient supply to achieve ideal product yield and quality.
6. Safety inspection and verification: • Ensure that all safety measures are in place, including over limit alarms and effective emergency stop functions, and conduct verification of CIP (Cleaning in Place) and SIP (Sterilization in Place) systems.
7. Performance evaluation and acceptance: • Test and evaluate various performance indicators of the bioreactor, record debugging results, and conduct formal acceptance after meeting design expectations and user requirements.
During the entire installation and debugging process, strict adherence to operating procedures and safety regulations should be followed. If necessary, manufacturer technical personnel should be invited to provide on-site guidance or cooperate with third-party testing agencies for acceptance. At the same time, a detailed equipment operation and maintenance manual should be established for long-term stable operation and troubleshooting in the future.
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
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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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