Large scale fermentation (1)

LARGE SCALE FERMENTATION

1. LARGE SCALE PRODUCTION
FERMENTER DESIGN AND ITS
VARIOUS CONTROLS

2. INTRODUCTION:
FERMENTATION:.
The chemical breakdown of a substance by
bacteria, yeasts, or other microorganisms,
typically involving effervescence and the giving
off of heat.
FERMENTER:
Fermenter or bioreactor is having closed
container with adequate aeration,agitation,pH&

3. ….
Temperature and drain or overflow vent to
removethe waste biomass of cultured
microorganisms along with their products.
It is extensively used for food processing,
fermentation &waste treatment.
SIZE OF FERMENTER:
From 1-2lit to 5,00,000 litres or even more up to
1.2 million litres have been used .

4. FERMENTER DESIGN:

5. …..

6. CONSTRUCTION:
It is majorly constructed with stainless steel for
industrial purposes.
It is a large cylinder closed at the top and bottom
and various pipes and valves are fitted into it.
Industrial fermentation is done in aerobic
process and the construction of typical aerobic
fermenter is the following,.

7. …..
i.cooling jacket
ii.aeration system
1.sparger
2.impeller(agitation)
iii.baffles
iv.controlling devices for environmental factors.

8. 1.COOLING JACKET:
The fermenter is fitted externally with cooling
jacket through which steam or cooling water to
run.
It is necessary because sterlization of the
nutrient medium and removal of the heat
generated are obligatory for successful
completion of the fermentation in the fermenter.

9. …….
2.Aeration system:
Critical part of fermenter
In a fermenter with a high microbial population
density,there is a tremendous oxygen demands
by the culture,but oxygen being poorly soluble in
water hardly transfers rapidly throughout the
growth medium.
Two separate aeration devices are used to,

10. ….
Ensure proper aeration on fermenter,
i.sparger(series of holes in metal rings)
ii.impeller( also called agitator)-device necessary
for stirring of fermenter. 1.it mixes
the gas bubbles through liquid culture medium.
2.it mixes the microbial cells through the liqiud
culture medium.In this way, the stirring ensure
uniform access of uniform cells to nutrients.

11. MEDIA:
There are two types of media is used in the
fermenter such as,.
I.synthetic media
II.non synthetic/crude media.
1.synthetic media
Media with all the requisite constituents in a pure
form in the desired proportion represents
synthetic media. Use of this type of media in
fermentations is not practicable

12. …...
2.non synthetic media
The non-synthetic media with naturally available sources
are better suited for fermentation.
In practice, crude media with an addition of requisite
synthetic constituents is ideal for good product yield in
fermentation. The
most frequently used substrates for industrial
fermentation with special reference to the supply of
carbon and nitrogen sources

13. …….
3.BAFFLES: The baffles are metal strips
normally incorporated into fermenters of all sizes
to prevent a vortex and to improve aeration
efficiency. 4.CONTROLLING
DEVICES FOR ENVIRONMENTAL
FACTORS:EVF that are frequently controlled
includes temp,O2 conc,pH,cell mass,levels of
key nutrients and product concentration.

14. ……...
5.USE OF COMPUTER IN FERMENTER:
Integration of computers into fermentation
system is based on the computer capacity for
the process monitoring, data acquisition, data
storage, error detection.
FACTORS TO BE CONSIDERED FOR DESIGN
OF FERMENTERS:.
1.maintenance of aerobic and anaerobic to
support the growth for optimum product

15. Formation...
2.maintenance of process tempreture at desired
level
3.maintenance of the culture in pure state
throughout the process.
GENERAL REQUIREMENTS FOR FERMENTATION:
1.fermentor tank should be operated aseptically for
long period of process.
2.adequate aeration and agitation should be provide
for metabolic requirements of microorganisms.

16. …..
3.power consumption should be low.
4.pH & temperature control.
5.sampling should be convenient.
6.evaporation loss from fermenters should not
be excessive.
7.minimal use of labour.
8.vessel should have smooth internal surfaces.

17. THANK YOU
By T. AB is HEK, b.pharm