Our company has installed and launched a pilot line for the fermentation synthesis of microorganisms. The pilot line consists of:
- Sterilizable-in-place fermentors with 30 and 300 liters of total volume;
- Sterilizable-in-place media preparation tank with a total volume of 50 liters;
- High-speed tubular centrifuge for the biomass concentration;
- Auxiliary equipment for steam, air and cooled water provision.
A distinctive feature of this line is its flexibility – it is possible to use all three tanks independently and perform different tasks on them simultaneously or at different time intervals.
BRS Biotech bioreactors are equipped with control systems of agitation speed, temperature, pressure, pH, dissolved oxygen, air flow through a rotameter and a mass flow meter.
For feeding at any time of cultivation, as well as for replacement of glass feeding bottles without violating sterility, two sterilizable-in-place feeding ports are installed on the bioreactors, sterilization is held automatically.
For the convenience of sampling at any time of fermentation, sterile sampling valves are installed on the bioreactors.
All vessels of fermentors have lid lifts for the convenience of washing, and each container is equipped with two CIP spray balls for the connecting to a CIP station.
Sterile product transfer lines are designed and installed between 30 liters fermenter and 300 liters fermenter, as well as sterile feeding line from 50 liters media preparation tank to fermenters.
Exhaust gas filter has electric jacket in order to prevent the filter from getting wet.
A centralized control system for the entire line with a remote workplace helps the operator to control the process both in the fermentation hall and outside it. Intuitive interface, hierarchical access structure helps to avoid mistakes when choosing equipment operating modes.
Among the features of the software, it is possible to note the possibility of cascade control of dissolved oxygen using:
- agitation speed,
- supplied gases (aeration),
- pressure,
- and the feeding mode of peristaltic pumps.
The biomass obtained as a result of microbiological synthesis is transferred to a high-speed tubular centrifuge for its concentration. The centrifuge has a cooling coil to prevent heating of the product in the rotor, smooth start and stop of the rotor rotation speed.
The equipment is designed, manufactured and installed in accordance with the technical specification of the client.
