MAGNETIC MIXERS
AERATION
TECHNOLOGICAL SKID
STAINLESS-STEEL VESSEL
MADE IN EUROPE
Novel magnetic coupling agitator – top or bottom mounted.
Aeration through ring sparger with aeration rate up to 2 vvm.
Sensors and valves ensure fully automated process control.
Vessel produced from certified surgical steel 316L
Manufactured in the EU, adhering to the highest standards of quality and innovation
Our configurator makes it easy to prepare a request and add additional features
Pilot Scale Bioreactors
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.
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.
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,
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Technological skid,
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Control cabinet with built in PLC and touch screen panel.
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.
Customisation and Features
CUSTOM PROGRAMING
ADD ANY SENSOR METERING
VARIOUS TYPES OF AGITATORS
Summary
Vessel design
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.
Main technical parameters:
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Total volume (L): 15 – 20000 (customizable)
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Working volume (L): 10 – 15000 (customizable)
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H/D range: 1.1 – 3.2 (customizable)
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316L SS for surfaces in contact with product (Surface roughness Ra ≤ 0.63 μm)
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304 SS all other surfaces (Surface roughness Ra ≤ 0.80 μm)
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All gaskets are FDA compliant
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Sight glass on the side wall
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Aseptic Tank Bottom valve
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Port connections: Tri-Clamp, Ingold
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Lid lifting device, hydraulic or electric (optionally)
Mixing
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.
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
Aeration through ring sparger with aeration rate up to 2 vvm.
Optionally air supply overlay, mass flow controllers (MFC), addition up to four different gases: (Oxygen, Nitrogen, Carbon Dioxide).
Aeration system includes:
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Filter-Regulator with pressure gauge for gas supply pressure setting
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Flow switch or rotameter to indicate gas flow rate in the range up to 2 vvm
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Mass Flow Control (optionally)
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Gas Mixing System (optionally)
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PTFE Membrane Filter Cartridges (0.2 μm) in SIP Stainless steel housings
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O2/CO2 concentration ratio in the exhaust (optionally)
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Automatic pressure control (optionally)
Control cabinet
Stainless steel control cabinet (Rittal, Germany) with built-in Siemens PLC and Weintek touch panel. Profinet connection to LAN or WAN
Sensors
Automatic process control is ensured by the following sensors:
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Temperature
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pH
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DO
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Alarm Level
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Foam Level
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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
In customized versions several optional sensors are available:
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Optical Density
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pCO2
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Other on request
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O2/CO2 gas analyzer
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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.
Technological skid
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.
Several processes can be performed in automatic mode:
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SIPF – Air Inlet and Outlet Filter sterilization
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SIPR&F – Reactor vessel sterilization
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Temperature maintenance
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Fermentation
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Pressure hold test
TO SEE OUR STANDARD OPTIONS CLICK HERE
Vessel design
Jacketed with heat insulation. Removable lid (up to 800 litres).
The hydraulic lifting device of the lid.
Vessels over 800 litres have manhole of corresponding size. Side glass on the lid and in the upper cylindrical part of the vessel.
Total volume (L)
15 – 20 000 (customized)
Working volume (L)
10 – 16 000 (customized)
Н/D range
1,1 – 3,2 (customized)
Surface quality
Inner vessel wall: surface roughness lower than 0.63 μm.
Outer vessel wall: surface roughness lower than 0.8 μm (passivated).
Materials
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The material of the parts, in contact with the product is stainless steel 316L;
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For parts, not in contact with the product (e.g., the jacket) – stainless steel 304;
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O-ring gaskets and membranes in contact with the product – EPDM, Silicone, Viton, PTFE
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Insulation – chlorine free mineral wool;
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Sight glass – borosilicate glass;
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Peristaltic pump tubing - platinum cured silicone
All bioreactors have insulation over the jacket. The outside surface of insulation is covered by stainless steel 304
Pressure and temperature
For all vessels the maximal design pressure inside the vessels – 3.5 bar, in jacket –4.0 bar (can be customized).
Maximal temperature - 135 °C.
Mixing
Novel magnetic coupling mixing with top- or bottom placed motor with reduction gear.
For microbial cultures 2 – 4 standard Rushton turbine type agitators are used for mixing media. To improve oxygen transfer rate an extra agitator can be added.
Optionally pitched blade or marine impellers for shear sensitive conditions, and special agitators for viscous media.
Mixer rotation speed maximal range (for standard Rushton turbine mixing system, can be customized):
Mixing speed depends on the design and size of the mixer
Aeration
The aeration system may be configured for both microbial and cell culture, and includes:
• Filter-Reducer with pressure gauge to set up supplied air pressure;
• Flow switch or MFC for measuring supplied air flow in the range of 0 - 2 vvm (volume of air per volume of fluid per minute);
Chemically inert PTFE membrane filter cartridges which are inherently hydrophobic used as air and gas-sterilizing filters for incoming and outgoing air. Filters are installed in the steam sterilizable stainless-steel housings;
• Automatic gas flow control system (e.g., O2, N2, CO2, NH3) using a mass flow controller (the MFC) (optional);
• The measurement of the O2 / CO2 concentration ratio in the exhaust air (optional);
• Automatic pressure control system in the fermenter vessel, mounted on the exhaust gas line (optional)
Automation
Siemens Simatic S7 - 1500 series PLC.
Touch panel 15” TFT, 1024 x 768mm, 262k colours
Frame
Stainless steel power cabinet
Communication
Profinet connection to LAN or WAN
Sensors (basic)
Temperature, pH, pO2, foam, alarm level, pressure
Sensors (optional)
Optical density, pCO2, O2 / CO2 gas analyser, redox potential, methanol, integrated weighing system.
Control of fermentation and sterilization processes
The following processes and parameters are controlled:
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Temperature, pH, pO2 (according cascade control), foaming, high level, inlet air or gas flow, overpressure (optional), methanol (optional) and ethanol (optional) concentrations;
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Substrate feeding according to adjusted profiles (optional)
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Fully automated sterilization in place of empty and filled (with substrate) vessel, including the sterilization of inlet and outlet
filters, and cooling of vessel after sterilization.