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Sterilization:
Fermentation is more successful in germ-free environments. That is to say, everything from the growth medium to the air used in the fermentation process to the bioreactor itself must be sterile.
In-situ sterilization:
The bioreactor's reaction vessel, which already contains the required medium, is surrounded by a jacket or coil through which pressurized steam is pumped. The setup is heated to around 120 degrees Celsius and held for about 20 minutes. To a certain extent, in-situ sterilizing is limited. The bioreactor is inefficient in energy use since it takes a long time to heat the system to 120°C (i.e., energy is squandered). Prolonged heating may harm vitamins in addition to precipitating the medium's ingredients.
Eternal heat sterilization:
Pressured steam is used to sterilize the inside of a basic bioreactor. Short exposure to the pressured steam infusion allows rapid heating to 140 degrees Celsius. Alternatively, the medium might be disinfected using a heat exchanger heated by compressed steam. The components of the medium do not precipitate when subjected to high temperatures for brief periods. The continuous heat sterilization technique also results in zero energy waste.
Immunization and sampling:
The bioreactor holds the growing medium under sterile conditions, ready for inoculation with the generating organism. The inoculum usually takes up between 1 and 10 percent of the total volume of the medium. A high-yielding manufacturing strain was lyophilized and then stored in liquid nitrogen or a deep freezer to ensure its viability for future use. Throughout the fermentation, samples are taken from the bioreactor at regular intervals. This is essential to assess the output and detect any contamination that may have occurred.
Aeration:
Aeration of the fermentation medium is required to provide oxygen to the producing organisms and remove carbon dioxide from the bioreactor. The aeration setup was designed with gas exchange in mind. Compressed oxygen from storage tanks is fed into the bioreactor through a sparger located at the vessel's base. Miniscule air bubbles go through the medium and surface at the top. The term "head space" describes the vacant space typically occupying the upper 20% or so of a bioreactor's capacity. The bioreactor is working at around 80% of its capacity. The gases created during fermentation accumulate in the headspace, which has an air outlet.
Suspended aeration system using air lift:
When using this method, the air is sparged into the bottom of the fermenter. This may cause rising bubbles of air. Increasing the fermenter's aeration capacity increases the amount of oxygen in the dissolved medium. The connection between airflow rate and internal pressure is simple when considering the air-lift system's aeration capability. The term "oxygen demand" describes the rate society requires oxygen. Because aerobic species can't grow if oxygen levels drop too low, the aeration capacity must be higher than the oxygen requirement (starvation).
Mixing and aerating system:
Some media benefit from being stirred to increase their aeration capacity. An option for doing this is to use impellers powered by motors. The aeration rate of a mixture in a stirred fermenter is determined by the airflow rate, the internal pressure, and the rate of stirring. Compared to stirred fermenters, air-lift fermenters aren't as well suited to produce high levels of aeration.
Methods of Control and Supervision:
Keeping the reaction vessel in an optimal growth environment for maximal product production is essential. Optimizing your fermentation results requires constant monitoring of critical parameters such as pH, temperature, dissolved oxygen, adequate mixing, nutrient concentration, and foam formation. Thanks to modern sensors, it is now possible to automatically and continuously track these metrics.
A good bioreactor manufacturer always considers the all above characteristics before manufacturing a bioreactor.
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| Akshay Thakur |
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