Pilotti Bioreaktorit

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:

  • Fermenter/Bioreactor vessel
  • Technological skid
  • 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.

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

  • 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)

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:fermenters/reactors

  • 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)

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:

  • 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

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.

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

  • SIPF – Air Inlet and Outlet Filter sterilization
  • SIPR&F – Reactor vessel sterilization
  • Temperature maintenance
  • Fermentation
  • Pressure hold test
 

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)

H/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

All bioreactors have insulation over the jacket. The outside surface of insulation is covered by stainless steel 304

  • The material of the parts, in contact with the product is stainless steel 316L;
  • For parts, not in contact with the product (e.g., the jacket) – stainless steel 304;
  • O-ring gaskets and membranes in contact with the product – EPDM, Silicone, Viton, PTFE
  • Insulation – chlorine free mineral wool;
  • Sight glass – borosilicate glass;
  • Peristaltic pump tubing – platinum cured silicone

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

15 – 20 000 (customized)

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

  • Temperature, pH, pO2 (according cascade control), foaming, high level, inlet air or gas flow, overpressure (optional), methanol (optional) and ethanol (optional) concentrations;
  • Substrate feeding according to adjusted profiles (optional)
  • Fully automated sterilization in place of empty and filled (with substrate) vessel, including the sterilization of inlet and outletfilters, and cooling of vessel after sterilization.