We manufacture, deliver and install patented novel magnetically coupled mixer drives.
This magnetically coupled drive is used in our manufactured bioreactors and can be acquired as a separate part for installation in any other manufacturer’s vessel.
The working principle of the novel magnetically coupled drive is based on rotating a pair of magnetic rotors (drive and driven magnets) inside and outside a hermetic cylindrical housing. The drive magnets interact with the outer rotors, which are placed on the opposite side of the hermetic housing and also are supplied with a set of magnets, which are encapsulated in the rotors shell. In result, by applying rotation to the drive magnets, thanks to the magnetic interaction, the outer rotors are rotated simultaneously, thus resulting in mixing.
A pair of two silicon carbide and zirconium oxide bushings is mounted on both sides of the outer rotor to provide long-term stable and clean rotation. The novel magnetically coupled mixer drive can be mounted either on the top or the bottom of the bioreactor.
The novel magnetic drive is easy scalable. Throughout the years, we have successfully applied such magnetic mixers in laboratory bioreactors of a 5 liter working volume and in industrial scale bioreactors until a working volume of 20 000 liters. Thanks to the implemented design, the stirrer operates as good as a conventional mechanical stirrer, but has the advantage of high sterility and low maintenance requirements, which makes it ideal for biotechnological and pharmaceutical applications.
We are convinced that this is not the highest reachable process volume in which the magnetically coupled mixer can be successfully installed and operated. In traditional magnetically coupled drives, the mixer vibrations at high rotation rates make the scale-up process to high volumes difficult. Using our novel magnetic drive, this problem is set aside, because torque from the drive magnets is directly transferred to the driven magnets (impeller magnets). Due to this, the novel drive, additionally, consumes about 30 % less electrical power than a conventional mechanically coupled stirrer.
The maximal torque of one pair of magnetic rotor depends of diameter of applied cylindrical drive housing (see table):
|Cylindrical housing diameter (mm)||Max. Torque (for one impeller), N*m|
To install this magnetic drive in bioreactors of any other manufacturer, it will be necessary to weld a flange in either the top or bottom lid of the vessel, according to the corresponding sizes. The flange size depends on the diameter of the desired cylindrical housing.
In case if the drive is meant to be installed on the top lid of the bioreactor, firstly, the static housing is inserted through the flange in to the vessel, then it is fixed in place. After that, the outer magnetic rotors with zirconium oxide and silicon carbide bushings are mounted on the housing. The installation is finished by connecting the appropriate motor and gearbox on the outer part of the flange (i.e. above the lid).
In case if the drive is meant to be installed on the bottom lid of the bioreactor, firstly, the motor and gearbox is mounted on the vessel’s bottom. After that, the static housing is inserted through the flange in to the vessel, and fixed in place. The next step is mounting the outer magnetic rotors with zirconium oxide and silicon carbide bushings on the cylindrical housing. The installation is finished by installing the baffles of the bioreactor.