by Fermentation is a process where microorganisms such as yeast or bacteria convert carbohydrates like sugar into other compounds and energy. It involves enzymatic bioconversion of carbohydrates to alcohols, organic acids and gases through microorganism activities under anaerobic conditions. Fermentation is a natural process and has been used for various applications like production of food, beverages, pharmaceuticals and industrial chemicals. Careful control of fermentation parameters inside it helps optimize the yield and quality of final products.
Types
Based on design and mode of operation, it can be classified into different types. Some common types are:
Batch Fermenters
They are simple in design where the entire process from inoculation to harvesting is carried out in a single operation. The Fermenter medium along with microorganisms is added to the its vessel in one batch. Environment conditions inside are controlled but there is no intermediate removal or addition of material during the process. This type is suitable for smaller scale production but is less productive than other advanced designs.
Fed-batch Fermenters
In this part of the Fermenter medium is added in increments over the fermentation period, usually when certain nutrients become limiting. This allows better control over the rate of substrate feeding and helps maintain optimal growth conditions for enhanced productivity. Compared to batch, a fed-batch process leads to higher product yields.
Continuous Fermenters
They offer maximum productivity advantages as the fermentation, in this case, is run like a steady-state biochemical reactor. Fresh medium is continuously added to the vessel while an equal amount of fermented broth is simultaneously removed. Microorganisms are immobilized on carriers so they remain inside during medium exchange. They are suitable for bulk production but require more complex control systems.
Factors influencing Design
The specific design of a it depends on various factors related to the fermentation process and production requirements:
Agitation & Aeration
Agitation and aeration systems play a key role in ensuring uniform mixing and dispersion of air/oxygen in the fermentation medium. Proper agitation and aeration are critical to support cell growth and metabolism. Different impeller systems and sparger designs are used for effective mixing and gas transfer.
Heat Transfer Systems
As fermentation is an exothermic process, heat transfer systems are incorporated in it for temperature control. Cooling jackets and thermal fluid circulation loops help regulate and maintain optimum temperatures ideal for microbial activity and product quality.
Sensors & Controllers
On-line sensors continuously monitor critical process parameters like pH, DO, temperature, and pressure inside the fermenter. Advanced control systems integrate real-time data from these sensors to automatically regulate auxiliary systems, ensuring process parameters are held within safe operating limits.
Sterilization Methods
Several sterilization techniques like steam, gamma irradiation or chemical sterilants are employed to sterilize it prior to inoculation to eliminate contaminating microbes. The method chosen depends on the design and thermo-sensitivity of ingredients.
Material of Construction
Fermenter vessels are fabricated from corrosion-resistant materials like stainless steel, glass-lined steel or specialized alloys depending on the nature of fermentation medium constituents to prevent leaching or toxicity issues.
Common Applications
Given below are some major industrial applications where fermenters play a crucial role:
– Production of antibiotics like penicillin via fungal fermentation processes
– Culturing of yeast and lactic acid bacteria to produce various types of beer, wine and fermented dairy products
– Manufacture of citric acid, gluconic acid, and other organic acids via fungal/bacterial fermentations
– Large-scale ethanol fuel production through saccharomyces cerevisiae fermentation of starches, sugars or cellulosic biomass
– Culturing of protozoa and algae to produce useful metabolites, proteins and pigments
– Vaccine production employing animal or insect cell culture fermentations
– Fermentative bioconversion of biomass waste to biogas through anaerobic digestion
– Nutraceutical extractions employing fungal or other fermentations
it provide the ideal controlled environment for large scale microbial fermentations which form the backbone of many big industries. Sound engineering coupled with automation guarantees optimal and consistent performance of fermentation processes to deliver high product yields economically. Advancements in fermenter technology will continue to aid development of safer, greener and more competitive fermentation industry globally.
*Note:
1. Source: Coherent Market Insights, Public Source, Desk Research
2. We have leveraged AI tools to mine information and compile it.
About Author - Priya Pandey
Priya Pandey is a dynamic and passionate editor with over three years of expertise in content editing and proofreading. Holding a bachelor's degree in biotechnology, Priya has a knack for making the content engaging. Her diverse portfolio includes editing documents across different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. Priya's meticulous attention to detail and commitment to excellence make her an invaluable asset in the world of content creation and refinement. LinkedIn Profile
