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Related Experiment Videos

Design and installation of a next generation pilot scale fermentation system.

B Junker1, T Brix, M Lester

  • 1Bioprocess Research and Development, Merck Research Laboratories, P.O. Box 2000, Rahway, New Jersey 07065, USA.

Biotechnology Progress
|June 7, 2003
PubMed
Summary

Four new fermenters and a PC/PLC control system were developed for industrial bioprocesses. The upgrades enhance secondary metabolite, bioconversion, and enzyme production efficiency while maintaining system compatibility.

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Area of Science:

  • Biotechnology and Biochemical Engineering
  • Industrial Microbiology
  • Process Control Systems

Background:

  • Existing industrial research fermentation pilot plant designed in the early 1980s.
  • Need for updated fermenter technology and control systems for enhanced bioprocesses.
  • Requirement to balance modernization with compatibility with existing infrastructure.

Purpose of the Study:

  • To design and construct four new fermenters for secondary metabolite cultivations, bioconversions, and enzyme production.
  • To implement a new PC/PLC-based control system for improved process management.
  • To integrate these new systems into an existing industrial research fermentation pilot plant.

Main Methods:

  • Design and construction of four novel fermenters.

Related Experiment Videos

  • Implementation of a new PC/PLC control system utilizing GE Fanuc PLCs, Genius I/O, and Fix Dynamics SCADA software.
  • Integration of new systems into an existing pilot plant, focusing on hardware and software compatibility.
  • Strategic material selection (e.g., Inconel) and piping layout for improved functionality and safety.

    • Main Results:

    • Successful design and construction of new fermenters and control system.
    • Enhanced capabilities for secondary metabolite, bioconversion, and enzyme production.
    • Improvements in corrosion resistance, safety (hazardous energy isolation), and instrumentation flexibility.
    • On-line calculation and control of nutrient feed rates for optimized bioprocesses.

    Conclusions:

    • The new fermenters and control system effectively enhance the capabilities of the industrial research fermentation pilot plant.
    • The design successfully balances the integration of modern technology with the preservation of existing infrastructure.
    • The implemented improvements offer greater efficiency, safety, and flexibility in bioprocess operations.