Industrial Fermenters

1. Industrial fermenters
Growing cells on a large scale

3. Industrial fermenters
Can hold up to 200 000 litres of culture
Cells are provided with nutrients and very
carefully controlled environment to keep
them in desired growth stage
Usually made out of stainless steel as many
fermentations produce acid.
Nutrients and other materials are fed in by
valve operated pipelines.

4. Industrial fermenters

5. Industrial fermenters
Conditions in the fermenter are carefully
monitored to regulate cell growth.
Fermenter and all pipework must be sterile
before fermentation begins
This is usually achieved by flushing the
whole system with superheated steam before
the production begins.

6. Industrial fermenters

7. Industrial fermenters
Interior is monitored by sterilisable probes
which record temp., pressure, stirrer speed,
pH, oxygen and carbon dioxide levels.
These are all recorded and electronic control
systems with automatic valves will regulate
them.
E.g. if medium becomes too acidic, bases can
be added from a reservoir to correct the pH

8. Industrial fermenters
A fermenter with a 30 000 gallon capacity

9. Industrial fermenters
The production of microbial products is called
fermentation but it is not fermentation in the
defined sense of the word.
Process if frequently aerobic so ferementer
has to be well aerated.
Incoming air is filtered and pumped into the
base of the fermenter – a valve releases the
pressure from the top f the tank.

10. Industrial fermenters

11. Industrial fermenters
The aeration will be sufficient to mix many
cultures
If the culture is thick or sticky additional
stirring is required by a motor driven paddle
called an impeller.
While initially the culture may need warming
to start of the process – once it has started a
cooling system is vital.

12. Industrial fermenters
Control panel for an industrial fermentation operation

13. Industrial fermenters
An antibiotic producing fermentation may use a tonne
of sugar a day.
The organisms are likely to raise the temperature of
the culture by more than 1
0
C per hour ; more heat will
come from the activity of the impeller.
This rise in temperature could quickly kill the
microbes if not cooled.
Cooling is achieved by either a water jacket or
cooling coils inside the fermenter.

14. Industrial fermenters

15. Industrial fermenters
Most fermentations are batch processes, e.g.
beer and wine, penicillin
Nutrients and the innoculum are added to the
sterile fermenter and left to get on with it!
Anti-foaming agent may be added.
Once the desired amount of product is present
in the fermenter the contents are drained off
and the product is extracted.

16. Industrial fermenters
Fermenters in an American winery

17. Industrial fermenters
Some products are made by a continuous
culture system.
There is a steady stream of nutrient input, and
spent medium is drained off.
Not many products are made this way but
manufacturers would like to be able to make
most products this way……..why?