Automated Bioreactor and Fermentation System with CIP/SIP

Product Introduction

The system consists of a hygienic stainless steel vessel, agitation assembly, temperature-control unit, gas-distribution module, feeding pumps, process sensors, sanitary piping, and an automated control cabinet.

During operation, online probes continuously measure the culture conditions. The control system compares the measured data with the preset recipe and automatically adjusts the relevant process modules.

For example:

• Heating and cooling maintain the required culture temperature.

• Acid, alkali, or gas addition regulates pH.

• Agitation speed, airflow, oxygen supply, and pressure regulate dissolved oxygen.

• Programmable pumps provide nutrients according to the feeding strategy.

• Antifoam agent can be added automatically when foam is detected.

• Alarm and interlock functions respond to abnormal operating conditions.

This closed-loop control reduces manual intervention and helps improve process stability, product yield, and batch reproducibility.

Main Features

1. Automated Process Control

The system supports real-time monitoring and automatic regulation of:

• Temperature

• pH

• Dissolved oxygen

• Agitation speed

• Aeration rate

• Vessel pressure

• Nutrient feeding

• Acid and alkali addition

• Antifoam addition

Control parameters and operating recipes can be configured according to different strains, cell lines, culture modes, and production processes.

2. Integrated CIP and SIP

Cleaning-in-Place and Sterilization-in-Place functions allow the vessel and connected piping to be cleaned and sterilized without extensive dismantling.

Automated sequences may include:

• Pre-rinsing

• Cleaning-agent circulation

• Intermediate rinsing

• Final rinsing

• Drainage

• Steam sterilization

• Temperature holding

• Cooling and cycle completion

This helps shorten batch changeover time and improve cleaning consistency.

3. Hygienic Vessel and Piping Design

The vessel and piping system are designed to minimize dead legs, residue accumulation, and difficult-to-clean areas.

Typical hygienic features include:

• Smooth internal surfaces

• Sanitary fittings and valves

• Drainable piping layout

• Sterile gas inlet and exhaust filtration

• Aseptic sampling connections

• Hygienic bottom discharge

• CIP spray devices

• SIP-compatible instruments

Material grade and surface-finish requirements can be customized according to the approved User Requirement Specification.

4. Flexible Agitation and Aeration

The agitation and gas-transfer systems can be selected according to the biological process.

Available configurations support:

• Microbial fermentation

• Mammalian cell culture

• Plant cell culture

• High-density fermentation

• Shear-sensitive cell processes

• High-viscosity materials

• Batch and fed-batch production

Impeller type, agitation speed, gas sparger, gas combination, and control strategy are customized according to oxygen-transfer and shear requirements.

5. Scalable System Configuration

The product can be configured for:

• Laboratory process development

• Pilot-scale verification

• Industrial manufacturing

• Single-vessel operation

• Multi-vessel production

• Integrated fermentation lines

Scale-up engineering can consider mixing time, oxygen-transfer capability, power input, heat-transfer load, tip speed, gas flow, and vessel geometry.

6. Intelligent Software Platform

The automated control platform may provide:

• Touchscreen operation

• Real-time process display

• Parameter trend curves

• Recipe management

• Alarm records

• Batch-data recording

• User-access control

• Historical-data review

• Remote monitoring

• Remote diagnostics

• Optional audit-trail functions

• Optional connection to SCADA, MES, or DCS

Reserved software and hardware interfaces allow the system to support future sensors, modules, and production-line expansion.