Fermenter
Fermentation Equipment
Fermentation Tank
Model: FMT Series
1. Product Overview
A Fermentation Tank (Bioreactor) is the core equipment in biological fermentation processes, providing a controlled optimal growth environment for microorganisms, cells, or enzymes to synthesize and accumulate metabolic products under optimal conditions. The fermentation tank is equipped with precise temperature control, pH adjustment, dissolved oxygen (DO) monitoring, agitation mixing, and sterile aeration systems to ensure stable operation under strict aseptic conditions. It is widely used in pharmaceuticals (antibiotics, vaccines, recombinant proteins), food (yogurt, soy sauce, MSG), chemicals (organic acids, enzyme preparations), and biofuels (ethanol, biogas), making it an indispensable piece of equipment for the modern biotechnology industry.
Key Features
- Fully aseptic design with SIP online sterilization at 121°C/0.1MPa to guarantee a sterile environment
- Precise temperature control ±0.2°C, PID regulation, jacket/coil cooling and heating
- Online DO monitoring with automatic cascade control (speed/airflow)
- Online pH monitoring with automatic acid/base addition
- Variable-frequency (VFD) agitation, speed adjustable 50–800rpm, adaptable to different fermentation processes
- Online foam detection and automatic antifoam control
- GMP/FDA compliant, supporting 21 CFR Part 11 data logging
2. Working Principle
Microbial Fermentation
The fermentation tank provides suitable culture conditions (temperature, pH, DO, nutrients) for microorganisms to proliferate and synthesize target metabolites. The agitation system breaks sterile air into fine bubbles, increasing gas-liquid contact area and oxygen transfer rate (OTR). The jacket or coil circulates cooling water/steam to maintain constant temperature. The pH electrode monitors in real-time with automatic acid/base addition. The antifoam system detects foam and adds antifoam agent automatically to prevent carry-over of broth into the exhaust line.
Cell Culture
Animal/plant cell culture uses low-shear agitation design (marine propeller, elephant ear impeller) to minimize mechanical damage to cells. In microcarrier culture, cells attach to microcarrier surfaces; agitation speed must keep microcarriers uniformly suspended without damaging cells. In perfusion mode, fresh medium is continuously fed while equal volume of spent medium is removed through a cell retention device, achieving high-density cell culture.
Enzyme Reaction
Free or immobilized enzymes catalyze substrate-to-product conversion in the fermentation tank (enzyme reactor). Enzyme reactions typically proceed under mild conditions (ambient temperature and pressure) with high specificity and minimal by-products. Free enzyme reactions use stirred tank configuration; immobilized enzymes use packed bed or fluidized bed. Temperature, pH, and substrate concentration must be precisely controlled to maintain enzyme activity and reaction rate.
3. System Classification
By Agitation Method
1. Mechanically Stirred Fermenter (Standard)
2. Air-Lift Fermenter
3. Self-Priming Fermenter
By Volume
1. Laboratory type (5–50L)
2. Pilot type (50–500L)
3. Production type (500–500000L)
By Application
1. Microbial Fermenter
2. Animal Cell Culture Bioreactor
3. Plant Cell Culture Bioreactor
4. Enzyme Reactor
4. Detailed Technical Parameters
Basic Parameters
| Parameter | Specification |
|---|---|
| Model | FMT-5 / FMT-50 / FMT-500 / FMT-5000 / FMT-50000 |
| Working Volume | 5–50000 L |
| Working Pressure | 0.05–0.15 MPa (Design 0.3 MPa) |
| Working Temperature | 5–130°C (Culture/Sterilization) |
| Agitation Speed | 50–800 rpm (VFD) |
| Aeration Rate | 0.5–2.0 VVM |
| pH Control Range | 2.0–12.0 |
| DO Range | 0–100% |
Mechanically Stirred Fermenter Parameters
| Model | Volume(L) | Speed(rpm) | Airflow(VVM) | Motor(kW) |
|---|---|---|---|---|
| FMT-5 | 3.5 | 50–800 | 0.5–2.0 | 0.37 |
| FMT-50 | 35 | 50–500 | 0.5–2.0 | 0.75 |
| FMT-500 | 350 | 50–300 | 0.5–1.5 | 3.0 |
| FMT-5000 | 3500 | 30–200 | 0.5–1.5 | 11 |
| FMT-50000 | 35000 | 20–150 | 0.3–1.0 | 55 |
Dimensions
| Model | Diameter(mm) | Body Height(mm) | Total Height(mm) |
|---|---|---|---|
| FMT-5 | 150 | 300 | 800 |
| FMT-50 | 350 | 700 | 1500 |
| FMT-500 | 800 | 1600 | 3500 |
| FMT-5000 | 1800 | 3600 | 6500 |
| FMT-50000 | 4000 | 7000 | 12000 |
Material Properties
| Component | Material | Description |
|---|---|---|
| Vessel | SUS316L | Electropolished Ra≤0.4μm, aseptic design |
| Jacket | SUS304 | Full jacket/half-pipe coil |
| Agitator Shaft | SUS316L | Double mechanical seal |
| Seals | Silicone/EPDM/PTFE | FDA certified, -20–200°C |
| Sight Glass | Borosilicate | Pressure rating 0.3MPa |
5. Core Component Selection
Vessel
SUS316L stainless steel, electropolished interior Ra≤0.4μm, no dead-leg design. H/D ratio 2:1–3:1 for optimal gas-liquid contact. Complete with manway, handhole, sight glass, and light port. SIP validated at 121°C/30min for aseptic performance.
Agitation System
Multi-stage impellers (disc turbine/pitched blade/marine propeller/elephant ear optional), double mechanical seal on agitator shaft for sterility. VFD motor, speed 50–800rpm adjustable. Impeller type and quantity selected based on process and vessel volume.
Aeration System
Sterile air passes through 0.22μm hydrophobic filter before entering through sparger ring or single-orifice tube at tank bottom. Air flow meter with manual/auto control. Large tanks equipped with air distributors for uniform bubble distribution. Exhaust with condenser and 0.22μm exhaust filter.
Temperature Control System
Jacket or half-pipe coil with cooling water/steam, PID control accuracy ±0.2°C. Small tanks use jacket cooling + electric heating; large tanks use coil + jacket combination. PT100 temperature sensor, 4–20mA output. Optional chiller or cooling tower.
Control System
SIEMENS/AB PLC controller, 10–15 inch touchscreen HMI. Real-time monitoring of temperature, pH, DO, speed, airflow, level, foam. PID auto-control with cascade regulation. Recipe management for 100+ process recipes. 21 CFR Part 11 compliant data logging, SCADA integration.
6. Typical Application Fields
Pharmaceutical Fermentation
Antibiotics (penicillin, erythromycin, gentamicin), vaccines (inactivated, recombinant), recombinant proteins (insulin, interferon, monoclonal antibodies), amino acids (lysine, glutamic acid), vitamins (B12, vitamin C precursor)
Food Fermentation
Yogurt and lactic acid beverages, soy sauce, MSG, beer and wine, mushroom liquid spawn
Chemical Fermentation
Organic acids (citric, lactic, itaconic), enzyme preparations (amylase, protease, cellulase), bioplastics (PHA, PLA), solvents (acetone, butanol, ethanol)
Biofuels
Fuel ethanol, biodiesel (microalgae culture), biogas fermentation, hydrogen fermentation
7. Design Standards & Certifications
Compliant with the following standards and certifications
1. GMP (Good Manufacturing Practice)
2. FDA 21 CFR Part 210/211
3. ASME BPE (Bioprocessing Equipment)
4. ISO 9001 / ISO 14001
5. CE Certification
6. GB 150-2011 Pressure Vessel
8. Custom Optional Configurations
| Option | Details |
|---|---|
| Volume | 5/10/30/50/100/300/500/1000/3000/5000/10000/20000/50000L |
| Impeller Type | Disc turbine/Pitched blade/Marine/Elephant ear/Ribbon |
| Shaft Seal | Double mechanical seal/Magnetic drive seal |
| Temp Control | Jacket/Coil/Half-pipe/Electric heating |
| pH Control | Online monitoring + auto acid/base addition |
| DO Control | Online monitoring + speed/airflow cascade |
| Antifoam | Conductivity probe + auto antifoam addition |
| Feed System | Single/multi-channel peristaltic pump auto feeding |
| Sampling | Sterile sampling valve/In-line sampling valve |
| CIP/SIP | CIP online cleaning/SIP online sterilization |
| Control | Manual/Semi-auto/Full-auto DCS |
| Explosion-proof | Ex d IIB T4 (optional) |
9. Warranty Terms
| Equipment Status | Warranty Period | Warranty Scope |
|---|---|---|
| New Equipment | 12 months | Vessel, agitation system, temp control, control system, sensors |
| Refurbished Equipment | 6 months | Agitation system, control system, sensors |
10. Packaging & Delivery
| Item | Packaging Method |
|---|---|
| Main Unit | Anti-rust treatment, plastic film wrapped, wooden crate |
| Sensors & Instruments | Individual shock-proof packaging |
| Electrical Cabinet | Moisture-proof, individually packaged |
| Documents | Waterproof bag sealed |
Lead time: New equipment 90–180 working days (depending on volume); Refurbished 45–90 working days.
11. Information Required for Inquiry
To receive an accurate quotation, please provide the following information:
Organism type (bacteria/fungi/cell cultures)
Target product name
Fermentation mode (batch/fed-batch/continuous)
Required working volume (L)
Working temperature and pressure
Agitation speed requirements
Aeration requirements
pH and DO control requirements
Material requirements (SUS304/SUS316L)
CIP/SIP requirements
Control mode preference
Local voltage and frequency
Explosion-proof requirements
Equipment preference: New/Refurbished
Budget range and brand preference
Delivery terms and destination port