Fully equipped bioreactor and control

EDF-5.4 is an autoclavable glass bioreactor with working volume till 4,5l (total volume 6,2 l, inside diameter 150 mm).

Laboratory bioreactor EDF-5.4 has two versions:

  • EDF5.4_1 for the cultivation of bacteria, yeasts and mycelial cultures;
  • EDF-5.4_2 for the cultivation of mammalian and plant cells.

 

EDF-5.4 has a compact, ergonomic and robust design. Glass cylinder vessel is mounted between the upper lid and the metallic jacketed bottom. The design of the bioreactor is easy to maintain and apply basic operations and preparatory process, in particular,
washing and autoclaving.

Novel magnetic coupling drive

Novel magnetic coupling drive

Mixer rushton turbine, pitched blades option depending from application

5L bioreactor rushton turbine
5L bioreactor pitched blade turbine

Sparger (ring sparger, microsparger) option depends on application

5l bioreactor sparger barbotier

No welded lid components – ideal for cleaning and sterility

Bioreactor top lid

Collapsible condenser allows decrease the height during autoclaving

Bioreactor condenser collapsible

Fed-batch according adjusted profiles

Bioreactor SCADA interface

Jacketed metallic bottom and bottom placed sterilizable sampler creates easy and robust
operational conditions

5L bioreactor sampler

Siemens Simatic S7-1500 based PLC

Bioreactor siemens simatic controller PLC

Recipe management, archiving and other possibilities in SCADA according to the requirements of 21 CFR Part 11

5L bioreactor SCADA interface

Extension and option possibilities

Gas mixing using mass flow controllers Hamilton ARC pH and DO sensors. These sensors send 4-20 mA signals directly to PLC and ensure at the same time information management via Bluetooth in smartphones or PC installed programs. This program generates a report about all calibration procedures, sterilization numbers, predicted service life.

Connection of additional sensors: culture turbidity (optical density), culture permittivity (viable cell density), conductivity, methanol/ethanol, off-gas analysis (O2, CO2, CH4), etc.

On-line/off-line data analysis and advanced process control possibilities using PC implemented program (Matlab, Python) algorithms communicating to process control system (PLC and SCADA).

Fully equipped bioreactor vessel

Fully equipped bioreactor vessel
Technical specification
Model EDF-5.4
Total volume (L) 6,2
Working volume (L) 2 – 4,5
Inside diameter (mm) 150
Inside height (mm) 350
Overall dimensions of the bioreactor (mm) 930 (W) x 800 (H) x 600 (D)
The minimum size of the autoclave chamber for vessel autoclaving (mm) 590 (Height) x 270 (Diameter)
Aeration, mixing
Aeration (standard) Supply and mixing two gases (air, O2) to ensure oxygen enrichment, including 2 pressure reducers with pressure gauges; 2 rotameters (for air 0 – 10 l/min for O2 0 - 5 l/min, can be customized to other ranges); microbiological filter; ring sparger (optionally microsparger); inlet gas filter; outlet gas filter with easy bending condenser; membrane valve and filter
Aeration (optionally) Separate gas or gas mixture supply to the surface of the culture
MFC for air, O2 or CO2
Gas mixing (air, N2, O2, CO2)
Mixing Top placed motor with novel magnetic drive
Impellers Two (6-blade) standard Rushton turbine type agitators for microbial cultures
Stirrers with inclined "propeller" blades for cell cultures to ensure gentle stirring regime (optionally)
Mixer rotation speed (rpm) 40 - 1000
Ports
For mixer/agitator drive; for pH, pO2, T, foam and liquid level sensors, port with three needles for introducing additives to control the pH, level and foam; hemostat tube for pumping of the product; aseptic pierceable membrane port, a port for the incoming gas with a filter of 0,2 micron, the condenser exhaust gas with a filter of 0,2 um, aseptic sampler; 2 spare ports closed with plugs
Bottom lid Metal bottom with jackets for temperature control
Autoclavable aseptic sampler
Control unit
Frame of the control unit Made from stainless steel A304, dimension 300 x 450 x 600 mm
Controller, control panel PLC- Siemens Simatic ET200SP (S7-1500 series);

Touch panel Weintek eMT3070, 5,7” TFT, 800x480, 16.7M colors

Communication 1) Ethernet connection to SCADA PC
2) Ethernet connection to IAN or WAN for remote maintenance
3)WiFi connection (VNC server) for smart phones and tablets
Sensors (standard) Temperature, pH, pO2, foam / liquid level
Sensors (optionally) Optical density, measuring the weight and volume of feeding components, Redox potential, pCO2, O2/CO2 gas analysis in the exhaust gas
Temperature control Built-in thermostat (heater – 500 W, chamber, recirculation pump, cooling water valve). Temperature control range from 5 °C till 55 °C above the chiller temperature. Measurement accuracy ± 0,1 °C; accuracy of temperature within the prescribed limits ± 0,2 °C
pO2 control Polarographic sterilizable pO2 sensor (Hamilton or equivalent, length 325 mm). Optionally pO2 optical sensor. Automatic pO2 cascade control. Limits of pO2 measurements: 0 – 150 % ( ± 1%) of saturation
pH control Sterilizable sensor (Hamilton or equivalent, length 325mm). Automatic control by acid and base peristaltic pumps. Optionally via CO2 or ammonia supply. pH control range 2 – 14 (± 0,02)
Foam, liquid level control Sensors based on measuring the electrical conductivity. Level control via peristaltic pump
Peristaltic pumps for introducing technological additives 4 freely configurable built-in pump with digital control (ON / OFF), and an analog supply pump with a constant flow rate of the solution (option)
Peristaltic pumps for introducing the substrate additives based on a given program An optional pump may be used with a variable feeding speed, controlled by the analogue signal from the control unit
Communication and data exchange Remote access system for wireless control of the cultivation process (via Wi-Fi) with the use of smart phones or tablets
Power supply Part of the electric power supply, 220 V, 50 Hz and has a built-in uninterruptible power supply (UPS)
SCADA software for the collection, processing, visualization and documentation of process data (optionally) SCADA BioRe for monitoring, reporting, archiving and full process control, develop according the requirements of 21 CFR Part 11 (code of federal regulation from US Food and Drugs Administration). Software development is based on ARC Informatique Pc Vue industrial development package and includes remote access via the Internet
Model based control (optionally) Model based fed-batch control, using supplement program, based on MATLAB and connected with SCADA trough OPC server