Solution for biological fermentation production line
One stop solution for large-scale biological fermentation production line (equipment section)
——Complete equipment list from 50 L seed tank to 200 m ³ production tank
1、 Overall Architecture
The production line is arranged in a three-stage manner of "upstream midstream downstream", supporting a three-level amplification of 50 L → 5 m ³ → 200 m ³, covering more than 20 types of fermentation products such as antibiotics, enzyme preparations, vaccines, food ingredients, and bio based chemicals. The single batch production capacity is 1-200 tons, and the annual production capacity can reach 50000 tons.
2、 Upstream engineering (seed preparation)
1. Bacterial/Cell Bank
-196 ℃ liquid nitrogen tank+QR code traceability to ensure that the bacterial strains remain active for 10 years.
2. Shake bottle cultivation
250 mL-3 L constant temperature shaker, amplitude 25 mm, speed 50-400 rpm, optional CO ₂.
3. Seed jar
50 L/300 L/1000 L magnetic stirring tank, 316L, Ra ≤ 0.4 μ m, SIP 125 ℃/30 min; pH、DO、 Temperature online, ± 0.2 ℃, ± 0.02 pH.
3、 Midstream Engineering (Main Fermentation)
1. Fermentation tank
• Specifications: 10 m ³, 50 m ³, 200 m ³ (can be connected in parallel to 4 × 200 m ³)
Structure: aspect ratio of 2.5-3:1, honeycomb jacket+outer half tube dual cooling, mechanical seal (double end face), top 0.22 μ m PTFE sterilization respirator.
Mixing: Double layered six blade Rushton+frequency converter 50-250 rpm, power 3-5 kW/m ³; Bottom microporous ring tube ventilation, saturated with dissolved oxygen>30%.
• Control: DCS+BioPAT ® MFCS， Real time acquisition of DO, pH, temperature, foam, pressure and weight; You can switch between batch, replenishment, and continuous modes with just one click.
CIP/SIP: 135 ℃ pure steam+alkali/acid cycle, cleaning coverage rate of 100%, validation cycle ≤ 2 hours.
2. Feeding system
6-way weighing and feeding: carbon source, nitrogen source, trace elements, pH regulator, defoamer, inducer; Measurement accuracy ± 0.2%, sterile diaphragm valve, zero dead angle sampling.
3. Air/exhaust treatment
Air compressor → freeze dryer → 0.01 μ m sterilization filter → fermentation tank;
The exhaust gas passes through a condenser and a 0.2 μ m filter, and the VOC of the exhaust gas is monitored online to meet the environmental VOC requirement of ≤ 50 mg/m ³.
4、 Downstream Engineering (Separation and Purification)
1. Solid liquid separation
Disc centrifuge 10000 g, continuous slag removal, suitable for high solid content of 30%.
Vacuum rotary drum filter with an area of 20 m ², operates continuously, and automatically cleans the filter cloth.
2. Cell fragmentation
High pressure homogenizer at 1500-2000 bar, flow rate of 1-20 t/h, ice water temperature control throughout the process<15 ℃.
Optional ultrasound or enzymatic hydrolysis tank for treating Gram positive bacteria.
3. Primary purification
5 m ³ flocculation sedimentation tank with pH adjustment and online turbidity control;
Ultrafiltration system TFF, membrane area 50-400 m ², tangential flow<3 bar, concentration 5-20 times;
Adsorption column: ion exchange/hydrophobic chromatography, 316L sanitary grade, capable of online CIP/SIP.
4. Purification and Finished Products
Nanofiltration/reverse osmosis: desalination, concentration to 50% solid content;
Vacuum belt dryer: Continuous drying at 60 ℃, moisture content ≤ 3%;
• Freeze drying: 20 m ² freeze dryer, -55 ℃ cold trap, with a powder retention rate of ≥ 80% of viable bacteria;
Dry granulation machine: Press the powder into 0.5-2 mm particles for easy transportation and instant dissolution.
5、 Public Works and Automation
• Steam: 6 t/h @ 8 bar, pure steam generator;
Ice water: -5 ℃ ethylene glycol 400 m ³/h, double plate exchange energy-saving;
Compressed air: oil-free 0.8 MPa, filtered through 0.01 μ m sterilization;
• Wastewater: MBR+RO reuse, COD <80 mg/L；
Automation: DCS+MES+SCADA, batch electronic signature, compliant with 21 CFR Part 11; Key valve dual power supply, UPS 30 minute guarantee.
6、 Typical case (200 m ³ × 4 parallel)
• Product: Food grade glucose oxidase
Single batch fermentation for 30 hours, enzyme production of 60000 U/mL
Annual production capacity of 35000 tons of fermentation broth → 6000 tons of concentrated enzyme broth → 1500 tons of dry powder
• Investment return period: 3.2 years (including civil engineering, public works, and verification)
7、 Summary
This large-scale biological fermentation production line is based on "standardized modules+flexible processes", which can switch 50 L seeds, 200 m ³ production, continuous feeding, downstream multi-path purification with one click. It is compatible with a full range of products from antibiotics to plant enzymes, vaccines to bio based chemicals, truly achieving "one factory, multiple products, rapid market launch".
