FERMENTATION TECHNOLOGY

• Fermentation is one of the oldest technologies used for food

preservation, and over the centuries, it has evolved, been refined
and diversified.
• Fermentation technology is defined as field that involves the use
of microbial enzymes for production of compounds that have
application within the energy production, material,
pharmaceutical industries, chemical, and food industries.
• Fermentation involves raising microorganisms in a nutrient
media by maintaining the physiochemical situation and thereby
converting feed into desired products.
• Fermentation has emerged as a prospective technology for the
manufacture of microbial foodstuffs feed, food, industrial
chemicals, and pharmaceutical products
• Fermentation takes place in large vessels (fermenter) with
volumes of up to 1,000 cubic meters.
 FERMENTOR/ BIOREACTOR DESIGN

• Fermenters are a type of closed-vessel with a controlled and

sterile environment for the growth of the microorganisms in
a liquid medium for the production of various compounds.
• Bioreactor is a device in which biochemical transformations
take place.
• The terms like bioreactors, microbial reactors, fermentors,
and biochemical reactors all have the same meaning.
• The main function of a fermenter is to provide a suitable
environment in which an organism can efficiently produce a
target product that may be cell biomass, a metabolite or
bioconversion product.
• Fermentor is designed in such a way that a higher value of
product could form by the microorganisms by utilizing a
small amount of media.
• The design and mode of operation of a bioreactor are based
on the production of an organism, optimum conditions
required for desired product formation, product value, and
its scale of production.
• A good bioreactor design will help to improve productivity
and provide higher quality products at lower prices.
• The sizes of bioreactors can vary widely depending on the
specific application.
• These sizes can range from small-scale fermenters for
microbial cells (few mm3) to shake flasks (100-1000 ml),
laboratory-scale fermenters (1-50 L), pilot-scale bioreactors
(0.3-10 m3), and even large-scale plant bioreactors (2-500
m3) for industrial production.
 Contin…
• Traditionally, fermenters have been open cylindrical
or rectangular vessels made from wood or stone.
• Small fermentation vessels of a few litres capacity are
constructed from glass and/or stainless steel.
• Pilot-scale and many production vessels are normally
made of stainless steel with polished internal surfaces,
whereas very large fermenters are often constructed
from mild steel lined with glass or plastic, in order to
reduce the cost.
 An Ideal bioreactor should be:

1. Aseptic Operation: The bioreactor vessel should be capable

of operating aseptically for a few days. This ensures that the
growth of microorganisms within the bioreactor remains free
from contamination, allowing for the production of desired
products without interference from unwanted organisms.
2. Proper Agitation and Aeration: Agitation ensures proper
mixing of cells and the growth medium, while aeration
supplies oxygen for aerobic fermentations. These processes
are vital for promoting optimal growth and metabolic activity
of the microorganisms.
3. Minimal Power Consumption: The bioreactor should be
designed to minimize power consumption while maintaining
optimal performance. This helps reduce energy costs and
enhances the economic feasibility of bioreactor operations.
4. Temperature and pH Control: Microorganisms have
specific temperature and pH requirements for optimal growth
and product formation.
5. Sampling Facilities: The bioreactor should have provisions
for easy and convenient sampling. Regular sampling allows
for monitoring and analysis of the growth and productivity of
the microorganisms, enabling process optimization and
quality control.
6. Low Evaporation Losses: Excessive evaporation can lead to
a loss of valuable products and adversely affect process
efficiency and productivity.
7. Minimal Labor Requirement: The bioreactor should require
minimal labor for production cleaning, harvesting, and
maintenance. This reduces labor costs and streamlines the
overall operation of the bioreactor system.
8. Smooth Internal Surfaces: to prevent the
accumulation of microorganisms or debris, ensuring
easy cleaning and maintenance.
9. Containment: The bioreactor should be designed to
prevent the leakage of viable cells from the
fermenter or downstream equipment. This ensures
the integrity of the production process and prevents
potential contamination.
 Components of a Fermentor
• A good fermenter must have the following features: Heat and
oxygen transfer settings Sterilization processes and foam
control, a fast and thorough cleaning system A proper
monitoring and control system.
• A typical fermentor of this type is an upright closed cylindrical
tank fitted with one or more baffles attached to the side of the
wall, a water jacket or coil for heating and/ or cooling, a device
for forcible aeration (known as sparger), a mechanical agitator
usually carrying a pair or more impellers, means of introducing
organisms and nutrients and of taking samples, and outlets for
exhaust gases.
• Modern fermentors are highly automated and usually have
means of continuously monitoring, controlling or recording pH,
oxidation-reduction potential, dissolved oxygen, effluent O2 and
CO2, and chemical components.
A TYPICAL BIOREACTOR
 1. Fermenter Vessel
• A fermenter is a large cylinder closed at the top and bottom connected with
various pipes and valves.
• The design of the vessel is intended to allow for work under controlled
conditions in bioprocesses.
• There are two main types of fermenter vessels used: glass vessels and
stainless steel vessels. Glass vessels are typically used in small-scale
industries. They are non-toxic and resistant to corrosion
• Stainless steel vessels, on the other hand, are commonly used in large-scale
industrial applications. They are designed to withstand high pressure and
resist corrosion. Stainless steel vessels are favored for their durability and
ability to handle the rigorous demands of large-scale fermentations. The
sterilization process for stainless steel vessels is typically performed in situ,
meaning within the vessel itself.
• The vessel is carefully designed to minimize maintenance and ensure
cleanliness during operation. The interior of the vessel is smooth to prevent
the accumulation of residues or contaminants
• In summary, fermenter vessels play a vital role in facilitating controlled
bioprocesses.
 2. Heating and Cooling Apparatus
• The fermentor vessel’s exterior is fitted with a cooling jacket that seals
the vessel and provides cooling water.
1. Cooling Jacket: The exterior of the fermentor vessel is equipped
with a cooling jacket, which seals the vessel and allows for the
circulation of cooling water. It helps regulate and control the
temperature inside the vessel.
2. Heat Supply: To provide heat within the fermentor vessel,
thermostatically controlled baths or internal coils are commonly
used. Thermostatically controlled baths ensure precise temperature
control by immersing the vessel in a temperature-controlled bath.
Internal coils, on the other hand, transfer heat directly to the
fermentor by circulating hot water or steam through the coils.
3. Heat Removal: Excess heat generated during fermentation needs
to be removed to maintain the desired temperature. Silicone
jackets are often employed for heat removal. These jackets, placed
around the vessel, are designed to dissipate excess heat and
maintain temperature control.
 3. Aeration System
• An aeration system is one of the very important parts
of a fermentor.
• It is important to choose a good aeration system to
ensure proper aeration and oxygen availability
throughout the culture.
• It contains two separate aeration devices (sparger and
impeller) to ensure proper aeration in a fermentor.
• The stirring accomplishes two things:
– It helps to mix the gas bubbles through the liquid
culture medium and
– It helps to mix the microbial cells through the
liquid culture medium which ensures the uniform
access of microbial cells to the nutrients.
 4. Baffles
• The baffles are important components
incorporated into fermenters to serve multiple
purposes, such as preventing the formation of
a vortex and improving aeration within the
fermenter.
• They are typically made of metal strips and
are attached radially to the wall of the
fermenter.
 Baffle cont’d
1. Vortex Prevention: The primary function of baffles is to prevent the
formation of a vortex or swirling motion in the liquid inside the fermenter. A
vortex can interfere with proper mixing and agitation of the fermentation
broth. By strategically placing the baffles, they disrupt the circular flow
patterns and promote more uniform mixing and circulation of the liquid.
2. Aeration Improvement: They help to distribute the incoming air or oxygen
evenly throughout the liquid medium, ensuring that the microorganisms
receive adequate oxygen for growth and metabolism.
3. Baffle Design: Baffles are typically constructed as flat metal strips that are
attached to the inner wall of the fermenter. The arrangement of the baffles is
designed to create a desired flow pattern that promotes efficient mixing and
aeration.
4. Baffle Material: Baffles are commonly made of materials such as stainless
steel or other corrosion-resistant metals. These materials are suitable for the
harsh and demanding conditions of the fermentation process, ensuring
longevity and resistance to corrosion.
 5. Impeller
• Impellers play a crucial role in the operation of fermenters by
ensuring the uniform suspension of microbial cells in various
nutrient media.
• They consist of blades attached to a motor on the lid of the
fermenter.
1. Suspension of Microbial Cells: The primary function of impellers
is to create agitation and mixing within the fermentation vessel,
ensuring that the microbial cells are uniformly suspended in the
nutrient medium.
2. Design and Construction: Impellers are typically composed of
blades that are attached to a central hub. The impeller assembly is
connected to a motor located on the lid of the fermenter.
3. Bubble Reduction and Distribution: Impeller blades also play a
critical role in reducing the size of air bubbles introduced during
aeration and distributing them uniformly throughout the
fermentation media
 6. Sparger
• A sparger plays a vital role in ensuring proper aeration
within a fermentation vessel by introducing sterile air.

• Aeration and Oxygen Supply: The primary function of a sparger

is to provide a controlled and sterile air supply to the fermentation
vessel. The sparger pipes are equipped with small holes, typically
measuring 5-10 mm in diameter, through which pressurized air is
released into the vessel.
 7. Feed Ports
• Feed ports play a crucial role in the operation of a fermentor by allowing
the addition of nutrients, acids, alkalis, or other substances necessary for
the fermentation process.
1. Nutrient Addition: Feed ports are used to introduce nutrient solutions into the
fermentor. These solutions contain essential components required for microbial
growth and metabolism. The nutrients can include sugars, salts, vitamins, and other
compounds necessary for the specific fermentation process.
2. Acid and Alkali Addition: In addition to nutrients, feed ports also enable the
controlled addition of acid or alkali solutions to the fermentor. This helps in
regulating the pH of the fermentation medium, as maintaining the optimal pH range
is crucial for the growth and activity of microorganisms.
3. Construction: Feed ports are typically designed as tubes made of silicone or other
suitable materials that are compatible with the fermentation process. Silicone is
commonly used due to its flexibility, chemical resistance, and ability to withstand
sterilization processes.
4. In-situ Sterilization: Before the addition or removal of products or nutrients through
the feed ports, in-situ sterilization is performed. This sterilization process ensures that
the added substances are free from contamination and do not introduce any unwanted
microorganisms into the fermentor.
 8. Foam-Control
• The level of foam in the vessel must be minimized to avoid contamination, this is
an important aspect of the fermentor.
• Foam control is a critical aspect of fermentor operation to prevent excessive
foam formation, which can lead to contamination and interfere with the proper
functioning of the fermentation process. :
1. Importance of Foam Control: Excessive foam in a fermentor can cause
problems such as blockage of air filters, loss of valuable product, and
contamination of surrounding equipment.
2. Foam-Sensing Unit: A foam-sensing unit is employed to detect the presence of
foam in the fermentor. It typically consists of sensors or probes that monitor the
foam level.
3. Control Unit: The foam-sensing unit is connected to a control unit, which
receives signals from the sensors and regulates the foam-controlling device.
4. Foam-Control Device: The foam-control device is usually mounted on top of
the fermentor, with an inlet that connects to the fermentor. Common foam-
control devices include foam breakers, foam traps, or foam skimmers. These
devices are designed to break down foam bubbles or capture and remove foam
from the fermentor, thus preventing excessive foam buildup.
 9. Valves
• Valves are used in the fermentor to control the movement of
liquid in the vessel, and they include:
1. Globe Valve: Globe valves are commonly used in fermentors for
their ability to provide precise flow control. They feature a
spherical-shaped body with an internal baffle and a movable plug
that regulates the flow through the valve.
2. Butterfly Valve: Butterfly valves are characterized by a disc-
shaped closure element that rotates within the valve body to
control the flow.
3. Ball Valve: Ball valves have a spherical closure element (a ball)
with a hole in the center. When the ball is aligned with the flow
path, the valve is open, and when rotated 90 degrees, the valve is
closed.
4. Diaphragm Valve: Diaphragm valves use a flexible diaphragm as
the closure element. These valves are suitable for controlling
corrosive or abrasive fluids.
5. Safety Valve: It is designed to automatically release excess
 10. Controlling Devices for
Environmental Factors
• A variety of devices are utilized to control environmental
elements like temperature, oxygen concentration, pH, cell mass,
essential nutrient levels, and product concentration.
• Thermostat: Monitors the temperature in the culture vessel.
• Foam probe: It senses foam formation.
• pH electrode: Monitors the pH in the culture vessel.
• Oxygen sensor: Maintains the dissolved oxygen content level.
• Heating pad: Provides heat to the medium.
• Cold finger: It is a pipe that passes cold water inside a vessel to
cool the contents.
• Pressure valve: Maintains the pressure.
• Air pump: Supplies air throughout the medium.
• Peristaltic pump: It pumps acid, base and antifoam into the
medium.
 11. Use of Computer in Fermenter
• For an efficient process, monitoring, and data collecting,
fermentors are generally coupled with modern automated and
semi-automated computers and databases.
• In case of fermentation system, a computer should consist of
programs and software which could analyze the generated data
and reproduce it as an understandable format.
• Thus, a powerful computer with more storage capacity and high
speed of performance could be best suited for automatization of
fermentation system.
• A computer system is accompanied with input and output port
which is used to transfer data and control signals to and fro
between computer and fermentor.