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Related Experiment Videos

A next generation, pilot-scale continuous sterilization system for fermentation media.

B Junker1, M Lester, T Brix

  • 1Bioprocess Research and Development, Merck Research Laboratories, RY810-127, P. O. Box 2000, Rahway, NJ 07065, USA. beth_junker@merck.com

Bioprocess and Biosystems Engineering
|February 24, 2006
PubMed
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A novel continuous sterilization system was developed for bioprocesses, enhancing media sterilization and control. This system retrofitted an existing pilot plant, improving effectiveness for metabolite, bioconversion, and enzyme production.

Area of Science:

  • Biotechnology and Biochemical Engineering
  • Process Control and Automation

Background:

  • Industrial research fermentation pilot plants require efficient and reliable media sterilization.
  • Existing systems may have limitations in control and effectiveness for advanced bioprocesses.
  • Retrofitting older facilities with modern technology is crucial for maintaining competitiveness.

Purpose of the Study:

  • To design, construct, and qualify a new continuous sterilization system for bioprocesses.
  • To upgrade the control system of an existing pilot plant for enhanced performance.
  • To characterize the performance of the new sterilization system under operational conditions.

Main Methods:

  • Design and implementation of a continuous sterilizer with sanitary heat exchanger (HEX) and flash cooling HEX.

Related Experiment Videos

  • Extension of an existing Honeywell Total Distributed Control 3000 system with redundant High performance Process Manager controllers.
  • On-line calculation of F(o) and R(o) values and use of field I/O modules for instrumentation.
  • Performance characterization over the operational range, quantifying deviations from design parameters.

    • Main Results:

    • Successful design, construction, startup, and qualification of the continuous sterilization system.
    • Enhanced control capabilities with 98 input/output (I/O) points and improved system integration.
    • Quantified differences between designed and observed temperature, pressure, and other profiles, with investigations into deviations.
    • Demonstrated effectiveness for media sterilization in secondary metabolite cultivations, bioconversions, and enzyme production.

    Conclusions:

    • The new continuous sterilization system and expanded control system effectively meet the demands of modern bioprocesses.
    • The retrofitted system demonstrates improved performance and reliability compared to prior installations.
    • The design strategies and implemented enhancements provide a robust solution for industrial research fermentation.