01 BIOREACTORS & FERMENTERS

Bioreactors & Fermenters

5 L to 200 m3. Sized on your oxygen demand and your organism - not on a catalogue.

Custom stainless steel stirred-tank bioreactors and fermenters for microbial fermentation, cell culture, biopharma and bio-manufacturing. SIP-sterilisable 316L product contact, laser-welded jackets, kLa-sized agitation, pH / DO control and IQ/OQ documentation.

Volumen de trabajo: 5 L-200 m3 | Sterilisation: SIP 121-134 C
Product contact: 316L, Ra <= 0.4 um | Documentation: IQ/OQ and FAT

02 MANUFACTURING CAPABILITY

A 30,000 m2 vessel shop that has been supplying fermentation and pharma plants since 2013.

30,000 m2

Purpose-built vessel and process-equipment shop in Jinan.

Since 2013

Design, fabrication, installation and commissioning.

316L contact

Hygienic product-contact construction and traceable materials.

CE / PED

Export engineering and pressure-vessel documentation.

100+ countries

International project delivery and support experience.

03 VESSEL TYPES

From bench trials to a 200 m3 train

The organism, product, oxygen demand, shear sensitivity and validation route determine the vessel type and the supporting skid package.

Bench & pilot fermenter

5 L-300 L vessels for process development, media studies and pilot campaigns. SIP-ready options, sanitary sampling and scalable instrumentation.

Seed fermenter

Seed trains from laboratory scale to production inoculation, with controlled transfer, sterile air and repeatable batch records.

Production stirred tank

1 m3-200 m3 microbial production fermenters sized on oxygen demand, broth rheology, kLa and heat load.

Cell culture bioreactor

Low-shear agitation, gentle sparging, tight temperature control and cleanable sterile boundaries for mammalian or insect cells.

Airlift & bubble column

Low-shear gas-driven circulation for selected organisms, products and cell-culture duties where mechanical agitation is not preferred.

Media, buffer & CIP/SIP skids

Supporting vessels, preparation tanks and utility skids for media, buffer, cleaning and steam-in-place sequences.

04 STERILE DESIGN

A bioreactor is a pressure vessel with one extra requirement: nothing gets in

Every penetration through the sterile boundary is treated as a process decision. We define the boundary, the SIP cycle, the cleanability and the documentation before fabrication.

Sterile boundary

A bioreactor is a pressure vessel with one extra requirement: nothing gets in. SIP coverage, drainability, slope, sanitary dead-leg control and sterile air protection are designed as one boundary.

SIP 121-134 C

Condensate drains from every low point, lines slope at least 1:100, and the vessel holds positive pressure with sterile air after cooling.

Hygienic details

316L contact surfaces, orbital or automatic welding, Ra <= 0.4 um finish, sanitary fittings and passivation records support repeatable cleaning.

05 PROCESS CALCULATION

Oxygen is what actually limits your batch

We calculate from your real process data rather than quoting a motor and impeller from vessel volume alone.

Oxygen transfer

Oxygen is what actually limits your batch. We size the vessel and sparger from OUR, broth viscosity, gas rate, kLa and the DO set point.

Impeller selection

Rushton, pitched-blade, hydrofoil, marine and custom impellers are selected for the organism, shear envelope, power per volume and mixing time.

Bubble size

Sparger geometry and gas velocity set the interfacial area. We check dispersion, flooding, foam and gas hold-up before quotation.

Heat removal

Fermentation makes heat. Jacket area, utility flow, insulation and the expected metabolic load are checked against the batch profile.

Required inputs: working volume, peak OUR or DO demand, broth viscosity, organism or cell type, aeration, agitation, feeding strategy, target temperature and sterilisation cycle.

06 ENGINEERING RANGE

Bioreactor size chart

Final dimensions, motor rating and instrumentation are calculated from your process data and validated against the approved URS and P&ID.

Scale	Working volume	Typical duty	Agitation / control
Bench	5-30 L	Organism screening and media studies	Small impeller, pH / DO / temperature
Pilot	50-300 L	Scale-up and pilot campaigns	SIP, sterile air, kLa study
Seed	0.3-5 m3	Inoculum train and transfer	Controlled agitation, SIP, transfer panel
Production	5-200 m3	Microbial or cell-culture production	PLC / HMI, recipe, batch records, IQ/OQ

07 CONTROL SYSTEM

The loops that keep a batch on trajectory

Siemens or Mitsubishi PLC with HMI or SCADA, closed loops for temperature, pH, dissolved oxygen, agitation, vessel pressure and air flow. Probes from Mettler Toledo, Hamilton or your existing brand can be specified.

Temperatura

Product temperature, jacket utility flow, heat load and alarm limits.

pH

Probe, acid / base dosing, calibration and recipe control.

Dissolved oxygen

DO cascade through agitation, airflow, oxygen enrichment and back pressure.

Pressure & airflow

Vessel pressure, sterile air by mass flow controller, exhaust and filter integrity.

Foam & level

Foam probe, antifoam dosing, level indication and high-level protection.

Batch records

Trends, audit trail, recipes, alarms, OPC UA and validation-ready reports.

08 FABRICATION

How a hygienic vessel is actually built

Inspection hold points keep material, welding, finish, control and test records traceable from plate intake to FAT.

Plate & component intake

316L heat numbers, thickness, fittings, valves, instruments and certificates are checked before release.

Laser cutting & forming

Shell, heads, openings and jackets are formed to the approved GA drawing and tolerances.

Orbital & automatic welding

Qualified procedures, controlled heat input, weld maps and traceable operators protect the sterile boundary.

Jacket laser welding

Heating and cooling channels are welded to the calculated pattern and independently tested.

Weld examination

Visual, penetrant, radiographic or borescope examination follows the inspection plan.

Polishing & passivation

Product-contact surfaces are polished, cleaned and passivated to the specified roughness.

Assembly & pressure test

Agitator, probes, valves, filters and panels are assembled before vessel and jacket testing.

FAT with water

Pressure, leak, control, mixing time, kLa, sterility hold and documentation checks are completed before shipping.

09 PROJECT REFERENCES

Vessels in service

Pilot, seed, production and fermentation vessels manufactured for brewing, beverage, bio-fermentation and process-equipment projects.

Pilot fermenter vessel

Production fermenter

Fermenter project installation

Stainless fermentation vessel project

10 PROJECT DELIVERY

From process data to a qualified vessel

01 Send process data

Working volume, organism, OUR, viscosity, DO and pH set points, feeding, aeration and sterilisation.

02 Calculation, P&ID, quotation

Process calculation, vessel selection, P&ID, GA drawing and an itemised technical quotation.

03 URS and drawing approval

Materials, nozzles, control system, documentation and inspection scope are frozen before production.

04 Fabrication

Traceable construction against the approved URS, P&ID, drawing and quality plan.

05 FAT and shipping

Pressure, controls, mixing, kLa, sterility hold and documents are reviewed before packing.

06 SAT, IQ/OQ, commissioning

On-site installation, commissioning, training and validation support where required.

11 BUYER QUESTIONS

Bioreactor FAQ

¿Cuál es la diferencia entre un fermentador y un biorreactor?

Ambos son recipientes destinados a procesos biológicos. Un biorreactor está diseñado para trabajos de cultivo microbiano o celular sometidos a un control riguroso, con esterilización, sensores y agitación a escala kLa. Un fermentador suele ser más sencillo. Los volúmenes de trabajo oscilan entre 5 L y 200 m³. Indícanos cuál es tu organismo y tu proceso.

¿Cómo se esteriliza el recipiente (SIP) y qué servicios auxiliares requiere este proceso?

Los recipientes están diseñados para la esterilización por vapor in situ a una temperatura de entre 121 y 134 °C, por lo que se necesita vapor limpio, un sistema de evacuación de condensado, agua de refrigeración y aire comprimido. Comprobamos los servicios de suministro necesarios para su proceso.

¿Qué sensores y circuitos de control vienen de serie?

Los circuitos típicos controlan la temperatura, el pH, el oxígeno disuelto, la presión, el nivel y la espuma. La lista exacta depende de tu proceso y se define en el presupuesto.

¿Qué materiales y acabados utilizas?

Las partes en contacto con el producto son de acero inoxidable 316L con interior pulido, camisas soldadas con láser y pasivación. Se suministran materiales trazables.

¿Qué documentación sobre las buenas prácticas de fabricación (GMP) pueden facilitar?

Podemos facilitar documentación de IQ/OQ, certificados de materiales, registros de soldaduras y ensayos, así como documentos de aceptación en fábrica. Los requisitos dependen de tu organismo regulador, así que indícanos cuál es tu norma.

How do you check mass transfer before shipment?

Agitation and aeration are sized from kLa, and tests are performed to agreed methods. Acceptance criteria are defined in the project documents.

12 REQUEST A QUOTATION

Send the process data. Get a calculation and a P&ID back in 48 hours.

You do not need a finished specification. Send the working volume, organism, oxygen demand, viscosity, agitation, aeration and sterilisation requirements. An engineer will review the duty and return the calculation, P&ID, drawing and itemised quotation.

Email: [email protected]
Phone: +86 15665777029
Factory: No. 9688, Jingshi West Road, Jinan, Shandong, China

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