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Pilot scale bioreactors

Pilot scale bioreactor

The Pilot scale series, in standard configuration, SIP fermenters/bioreactors are available in a wide range of working volumes from 10 – 15000 L liters, with multiple variations and customization options. Choose one of the Standard versions of Pilot Scale fermenters/bioreactors or customize Your own using the configurator. All pilot bioreactors are fully custom made to meet your specific needs.

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The models with working volume from 10 to 350 L are the perfect choice for scaling up bioprocesses from Lab scale and for initiating a small scale production before industrial scale-up. For larger volume fermenters/bioreactors use our configurator to specify reactor design or send Your request via email with Technical Specification and requirements.

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All stainless-steel bioreactors with working volume from 10 – 15000 L are autonomous and consist of three main parts:

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  • Fermenter/Bioreactor vessel,

  • Technological skid,

  • Control cabinet with built in PLC and touch screen panel.

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Technological skid and fermenter/bioreactor vessel can be interconnected with Corrugated PTFE hoses reinforced with single stainless steel (AISI 304) braid or could be integrated within a single frame.

Vessel design

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Fermenter/Bioreactor vessel has an insulated jacket. (Insulation – mineral wool) thickness varies from 50 to 100 mm. Insulation is plated with Stainless steel (AISI 304). Vessel can be equipped with flat or torispherically flanged, moveable lid (till 800 L). Larger vessels are equipped with a manhole of corresponding size to ensure serviceability and maintenance.

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Main technical parameters:

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  • Total volume (L): 15 – 20000 (customizable)

  • Working volume (L): 10 – 15000 (customizable)

  • H/D range: 1.1 – 3.2 (customizable)

  • 316L SS for surfaces in contact with product (Surface roughness Ra ≤ 0.63 μm)

  • 304 SS all other surfaces (Surface roughness Ra ≤ 0.80 μm)

  • All gaskets are FDA compliant

  • Sight glass on the side wall

  • Aseptic Tank Bottom valve

  • Port connections: Tri-Clamp, Ingold

  • Lid lifting device, hydraulic or electric (optionally)

Pilot bioreactor vessel inside
Pilot bioreactor technological skid
Pilot bioreactor automation and control panel
Pilot bioreactor lid and accessories
Pilot bioreactor with lifted lid

Mixing

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Novel magnetic coupling agitator – top or bottom mounted. For microbial cultures 2-3 Rushton turbines are used to mix the media. Optionally pitched blade or marine impellers are available for shear sensitive conditions.

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Agitator speed range for various working volume fermenters/reactors:

 

10 to 50 L: 750 rpm

70 to 150 L: 650 rpm

200 to 300 L: 600 rpm

400 to 650 L: 450 rpm

700 to 1000 L: 320 rpm

2500 L: 200 rpm

4000 L: 180 rpm

10000 L: 120 rpm

15000 L: 100 rpm

 

Aeration

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Aeration through ring sparger with aeration rate up to 2 vvm.

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Optionally air supply overlay, mass flow controllers (MFC), addition up to four different gases: (Oxygen, Nitrogen, Carbon Dioxide).

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Aeration system includes:

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  • Filter-Regulator with pressure gauge for gas supply pressure setting

  • Flow switch or rotameter to indicate gas flow rate in the range up to 2 vvm

  • Mass Flow Control (optionally)

  • Gas Mixing System (optionally)

  • PTFE Membrane Filter Cartridges (0.2 μm) in SIP Stainless steel housings

  • O2/CO2 concentration ratio in the exhaust (optionally)

  • Automatic pressure control (optionally)

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Technological skid

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Technological skid – system of pipes, valves and sensors which ensure supply of technological medias to the vessel – air, steam, clean steam, water as well as cooling water and condensate return from the system. Sensors and valves ensure fully automated process control.

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Several processes can be performed in automatic mode:

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  • SIPF – Air Inlet and Outlet Filter sterilization

  • SIPR&F – Reactor vessel sterilization

  • Temperature maintenance

  • Fermentation

  • Pressure hold test

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Control cabinet

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Stainless steel control cabinet (Rittal, Germany) with built-in Siemens PLC and Weintek touch panel. Profinet connection to LAN or WAN

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Sensors

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Automatic process control is ensured by the following sensors:

 

  • Temperature

  • pH

  • DO

  • Alarm Level

  • Foam Level

  • Pressure*

*Remark. Pressure sensors are installed at the bottom of the vessel and on the top lid for overpressure control (optionally) and for indicative volume/level measurement

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In customized versions several optional sensors are available:

 

  • Optical Density

  • pCO2

  • Other on request

  • O2/CO2 gas analyzer

  • Methanol sensor

 

Technical Specification describes Pilot Scale fermenters/bioreactors with working volume from 10 – 350 liters in Standard configurations. For customization or different configuration purposes use our configurator to prepare Your request.

To specify reactor design and price please contact us or use our configurator to specify options:

Take a look at an example of a user manual for more detailed information

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