Seed fermentor

Types of seed fermentors

Seed fermentor are used in a variety of applications to promote the growth of microorganisms. The following are the main types:

• Industrial scale seed fermentor

  Industrial-scale fermentation seed bioreactors help cultivate microorganisms on a larger scale for commercial use. This fermentor is implemented in the food industry to manufacture products like probiotics and fermented beverages. In the pharmaceutical industry, they are essential for producing antibiotics, hormones, and vaccines. Their capacity and efficient control systems make them suitable for meeting high production demands while ensuring product quality and consistency.

• Lab scale seed fermentor

  Lab-scale fermentation seed bioreactors are small-sized units that enable the cultivation of microorganisms in controlled lab settings. These bioreactors are used for research and development purposes, allowing scientists to optimize fermentation processes, study microbial behavior, and scale up successful protocols. By simulating industrial conditions on a smaller scale, lab-scale seed fermentors contribute to strain selection, process optimization, and formulation development before transitioning to larger-scale production.

• Modular seed fermentors

  Modular seed fermentor systems offer flexible platforms for cultivating various microorganisms by easily changing the fermentation modules. These modular systems adapt to different microbial growth requirements, such as temperature, pH, and nutrient supply. They are cost-effective solutions that save space and meet diverse fermentation needs. Moreover, the sterilization process of these modular systems is greatly simplified, ensuring optimal microbial growth conditions.

• Sterile seed fermentors

  Sterile seed fermentor bioreactors provide contamination-free environments for cultivating microorganisms. These bioreactors are crucial for industries where product purity is paramount, such as pharmaceuticals and biotechnology. By maintaining sterility throughout the fermentation process, seed fermentors ensure the exclusive growth of targeted strains, minimizing the risk of microbial contamination and ensuring the safety and efficacy of the final products.

Specification and maintenance of seed fermentors

The seed fermentor comprises different specifications indicative of its performance in the industry.

• Culture volume: Every seed fermentor has an optimal culture volume, ranging from a few milliliters to several liters. The selection of the culture volume is subject to the requirements of the subsequent fermentation process as well as the scale of production.
• Agitation system: The seed fermentor has an agitation system, which may take the form of mechanical stirrers, as the stirrer motors and other technologies. The function of the agitation system is to ensure that the culture medium is evenly mixed and dispersed.
• Temperature control: The seed fermentor is equipped with temperature controllers, such as thermostatic water tanks and refrigeration units, which can maintain the device at a constant temperature. This enables the growth of microorganisms at the desired temperature.
• Control system: The control system of the seed fermentor may be an intelligent automatic control system or a simple manual control system. The control system can monitor and adjust various parameters of the fermentor, such as temperature, pH value, dissolved oxygen content, etc.
• Sterilization function: Some seed fermentors are equipped with sterilization functions that can sterilize the culture medium and equipment in the fermentor. This ensures that the seed fermentor remains free from contamination.

In order to ensure that seed fermentors are operating stably and reliably over a long period of time, it is essential to perform regular maintenance and inspection of these devices. On the premise that the operators have firm command of the structure and operation manuals of fermentors, they are supposed to perform the following maintenance and care tasks:

• Clean: The exterior and interior of seed fermentors should be regularly cleaned and sterilized in order to prevent cross-contamination and ensure that they are remaining sterile. Cleaning agents and sterilization methods should be selected according to the type of seed fermentor and the process requirements. Moreover, the culture medium and residues in the fermentors should be thoroughly rinsed and cleaned up.
• Check: The operators ought to check seed fermentors and relevant accessories regularly, such as the supply of electricity and water, agitation systems, temperature control devices, etc. This is to ensure that they are operating stably and nicely and that the connection and performance of the accessories parts are well.
• Calibrate: The key parameters of seed fermentors, such as temperature, pH value, dissolved oxygen content, etc., should be calibrated and adjusted periodically so as to make sure these key factors within the ideal range for the growth and reproduction of microorganisms.
• Sterilize: The operators should sterilize seed fermentors on a regular basis, which includes cleaning and sterilizing the inner wall of the seed fermentor and the accessories and pipelines. Sterilization methods could include heat sterilization, chemical sterilization, etc.
• Lubricate: Some movable parts of the seed fermentor, such as motors and stirring axles, need lubrication in order to keep the equipment functioning well for a long time period. The appropriate lubricating oil should be selected, and its application should be kept in accordance with the relevant instructions for use and the process requirements.

Applications of seed fermentors

Seed fermentors are characteristic equipment used in various industrial processes, primarily for microbiological fermentation. Here are some typical applications of seed fermentors:

• Food and Beverage Industry: Seed fermentors are used to culture microorganisms and produce various foods and beverages. For example, they can be used to make fermented foods like yogurt, cheese, sauerkraut, etc. They are also employed in brewing and fermenting industries for beer, wine, and distilled liquor fermentation and for baking and brewing to culture yeast.
• Pharmaceutical Industry: Seed fermentors play a vital role in the pharmaceutical industry. They are used to culture microorganisms to produce antibiotics, vaccines, and other pharmaceutical drugs and to develop and produce biologic drugs, such as monoclonal antibodies and therapeutic proteins, via microbial fermentation.
• Biotechnology Industry: Seed fermentors are essential in biotechnology applications. They can be used to produce enzymes, amino acids, organic acids, and other biochemicals through microbial fermentation. In addition, seed fermentors can culture cells and microorganisms to produce biofuels like ethanol, butanol, and biodiesel via fermentation processes, and they can also be used in wastewater treatment to stimulate the growth of beneficial microorganisms to decompose organic pollutants.
• Agricultural Industry: In agriculture, seed fermentors can be used to produce probiotic additives and fermented feed for livestock. They can improve the digestion and health of animals by introducing beneficial microorganisms.

How to choose seed fermentors

Generally, the following factors and features of seed fermentors should be kept in mind when choosing the right fermentor for one's specific application.

• Production goal: The main objective or goal of the operation should be kept in mind and what role the seed fermentor will play in reaching those goals. The key role may be to multiply microbial cultures to high density to ensure sufficient inoculum size for the subsequent full-scale production fermentors. Or, the aim may be to optimize the culturing parameters so that the microbial growth will be at the maximum level possible. The selection of seed fermentor model will depend on the goal that the buyer is trying to achieve.
• Microbial culture: The type of microbial culture that is usually grown in the seed fermentor should also be a factor in the choice of the seed fermentor model. Different cultures have diverse nutritional or environmental needs, and some may require special features such as sterilizable in place (SIP) filters or specific feeding strategies like chemostat or batch culture.
• System integration: The seed fermentor that is chosen should be able to integrate well with the overall process system that is being used for culture growth and micro-organism harvesting. In some cases, the fermentor may have to be linked up with more than one separate piece of machinery and equipment, such as pre-treatment units, downstream processing modules, and separation systems. Thus, the selected seed fermentor must ensure smooth and trouble-free connectivity between all the different individual parts of the whole industrial organism-processing system.
• Automation and control: The chosen seed fermentor must have automated control features and redesigned user-friendly software tools to ensure optimum reproducibility of all process parameters and ease of fermentation monitoring. The controls should be intuitive, and the data can be and should be easily accessible for routine analysis and also for reporting purposes. The whole process of fermenting the organic materials should be streamlined and effortless so that the workforce can focus on value-adding tasks instead of menial, low-skilled and unutilized work.
• Scalability: The seed fermentor that is chosen should be able to be up-scaled or down-scaled, as the situation demands, without any hiccups, interruptions or problems. This ensures that the same technical specifications and cultural methods can be applied at various fermenting capacities, ranging from the small pilot scale to large commercial-scale units. The ability to increase or decrease the amount of culture that can be reared should give the business buyer flexibility in terms of operation, processing and ultimately also profitability.

Seed fermentor FAQ

Q1: How are seeds added to the fermentor?

A1: Seeds are usually added a few minutes after the fermentation process has begun. The addition of the seeds is done through the top of the fermentor by opening the manhole. When adding seeds, it is important to avoid stopping or slowing down the stirring system.

Q2: How are temperature and humidity controlled in a seed fermentor?

A2: The seed fermentor's temperature can be controlled through the cooling jackets. In most fermentors, there are cooling jackets that remove the heat generated during the fermentation. Also, the temperature can be controlled by using external chillers connected to the fermentor. Humidity controlling happens by adjusting the humidifiers and the ventilators within the fermentor. The ventilators can be adjusted to increase or reduce the air circulation. The vent hole can also be used to regulate the moisture within the fermentor.

Q3: How is the mixing done in a seed fermentor?

A3: Mixing in a seed fermentor can be done by stirring which involve the turning of the fermentor thus uniformly stirring the contents. In some fermentors there are mechanical agitators which are used to stir the seeds and the substratum uniformly. Another way of mixing the seeds is by using air lifts which are vertical tubes that move the substratum and the seeds upwards whoile mixing them. There are also external pumps which are used to recirculate the substratum thus mixing the seeds evenly.

Q4: How are the Fermentor seed companies chosen?

A4: When sourcing for a fermentor seed supplier it is important to consider the quality and the technology for the fermentors. Choose the suppliers who offer fermentors with advanced controls, monitoring as well as automation technologies. Also, consider the experience and the expertise of the supplier. Choose supplier who has a reputable standing in the market. The supplier should have the experience in the manufacturing of seed fermentors. In addition the support and the after sale services offered by the supplier should be considered. The supplier should have a reliable technical support and a good after sale service for the customers.