Industrial Bioreactors

For Manufacturing. Bioprocessing Lines from A to Z.

COMPLETE
CYCLE

Design, layout, installation, and process validation ensured.

GLOBAL
EXPERIENCE

Innovative systems operational globally and expanding.

FULLY
AUTOMATED

for SIP, CIP, fed-batch, and DO cascade systems.

FULL SYSTEM
INTEGRATION

Integrating new solutions into existing systems.

AUTOMATED
CIP CLEANING

CIP solutions eliminate time-intensive manual cleaning.

Application of stainless-steel bioreactors Stainless-steel bioreactors have a wide range of uses and are tailor-made each specific process

Industrial Bioreactors Ordering process

Design, layout, installation, and process validation ensured from A to Z.

Fully Automated Bioprocess

Setup Sample

Control cabinet is made from stainless steel and includes the following elements:

Basic Package

The basic package includes controlled parameters:

Custom controls and parameters available upon request!

PLC can be connected to network of Profinet and Ethernet for communication with other devices (bioreactors, CIP/SIP, SCADA etc.). Profibus connection to LAN or WAN. MODBUS protocol via TCI/IP

The design of all parts can be customized, and the selected brands can be adapted depending on requirements.

SCADA

Basic Setup

SCADA software is simple, uses MODBUS for data exchange, and offers data visualization, archivation, bioreactor status, ASCII data export, and remote access.

Setup Sample

The specialized software aligns with 21 CFR Part 11 requirements and is built on ARC Informatique PC Vue. Includes Dream Reports for audit trials and it offers data visualization, archiving, bioreactor status tracking, data export, device control, alarm management, and secure user access. It’s compatible with popular PLCs like Siemens Simatic and can connect via OPC server for broader integration.

Automated CIP Bioreactor Cleaning

We have a selection of CIP (Cleaning-in-Place) equipment available in two different types:

This CIP (Cleaning-in-Place) system is designed to be mobile and can be easily moved between production units. It can be connected to fermenters or other technological bioreactors and can achieve a maximum detergent circulation speed of 5000 L/h, ensuring fast and efficient cleaning.

The system includes:

This configuration allows for the effective cleaning of fermenters and other equipment with total volumes ranging from 20 up to 1000 litres.

Past Expertise

Complex bioreactor lines for biotechnological production

We have over 40 customers in 15 countries. Many customers start the development of cultivation technologies using our laboratory bioreactors and continue production and applications in manufacturing scale with our devices

We ensure full service for our bioreactors application projects, including development of project and qualification documentation, manufacturing the equipment and providing the delivery/montage/start up.

See our projects below or in our catalogue:

Vaccines

This closed system for animal vaccines includes two identical manufacturing lines with bioreactors of various volumes –

Heat-insulated pipelines, aseptic valves, and CIP/SIP systems for cleaning and sterilization.

The control system is three-tiered: 

local automation, central control, and SCADA software compliant with 21CFR Part11 (US FDA) for visualization, control, and secure access. SCADA’s features encompass process selection, recipe storage, visualization, data archiving, and remote access. Combining localized and central control ensures efficient process management, reduces operator errors, and adheres to current GMP standards.

Substances for Remediation oil of oil pollution

The application of this fermentation system is remediation of soil, contaminated with oil over a long period. In this system bacteria consortium have been cultivated, which has been isolated from oil-contaminated soil.

Fermentation system consists of 30, 100 and 800 liter bioreactors.

Another 800 liter reactor is used for storage of a substrate. In every bioreactor is temperature, pH, pO2, foam and level control, as well as time profiles of automatic substrate feeding rate can be adjusted. The sterilization possibility of all fermentation system including pipelines is ensured.

Ferments for Dairy industry

This system is used for the production of ferments for dairy industry, using the following microorganisms:

Lactococcuslactis, Streptococcus thermophilus and Candida strains.

The line consists of seeding-fermenter with working volume of 10 and 100 liters and one production fermenter with working volume of 1000 liters; 100, 150 and 1000 l bioreactors intended for medium preparation, as well as aseptic technological solution and product storage. All fermenters are connected in a technological line via pipelines to ensure cleaning and sterilization with CIP/SIP equipment. Technological line cleaning is performed with two mobile CIP devices. Data collection, processing and documentation is performed with a help of SCADA software, which can be installed on a user’s computer.

Whey waste recycling

The technology of whey processing is advancing to produce high-value products like whey protein, but side products like whey lactose pose environmental challenges.

A unique lactose processing method using yeast strains to produce food-grade yeasts. Their production system features bioreactors of various sizes, including a novel magnetic mixer in a 15,000-liter bioreactor. The system is automated, ensuring sterile transport and cleaning. Individual bioreactors use Siemens Simatic S7-300 for localized control, while a central control manages connections between bioreactors and software SCADA, controlling processes like cleaning, sterilization, and media feed.

BIO-Fertilizers

Two bioreactor lines are installed to manufacture biological products that increase soil fertility, restore its natural balance and increase plant productivity.

The main products consist of bacteria that fix nitrogen, release phosphorus, increase potassium absorption and restrict plant diseases that are caused by fungi.

First line consists of 50, 500 and 5000 liter bioreactors, but second line consists of 50, 500, 5000 and 20000 liter bioreactors. In all bioreactors are installed novel magnetic drive mixers (also in 20 000 liter bioreactor!) The systems are fully closed and all operation between bioreactors, CIP, SIP and mixing bioreactors are completely automated.

Bioleaching

Bioleaching uses microorganisms to extract metals from ores, applicable to metals like copper, zinc, and gold

We’ve designed bioreactor systems for bioleaching, including two configurations: eight 6-liter bioreactors with parts made of chemical-resistant materials and three larger bioreactors, with 30 to 80-liter capacity, connected either by pumps or gravity. These systems aid in developing bioleaching technologies and can be customized. This equipment was created for an EU project in collaboration with JSC “Biotehniskais centrs”, “Bor” Institute, and “Mintek”.

Enzymes and proteins from Pichia pastoris

This bioreactor line cultivates Pichia pastoris for enzymes and proteins. It’s automated with 50, 500, and 2×5000 litre bioreactors –

CIP/SIP systems, a circulation sterilizer, feeding reactors, and controlled valves. Parameters like temperature, pH, and methanol concentration are monitored. The control system is SCADA-compliant with 21 CFR Part 11.