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Lecture 3

Fermentors, or bioreactors, are sterilized vessels used for growing microorganisms under optimal conditions for commercial metabolite production, with various types including Continuous Stirred-Tank, Airlift, Packed Bed, Fluidised Bed, Membrane, and Bubble Column fermentors. The document distinguishes between fermenters, which are specifically designed for fermentation processes, and bioreactors, which are more versatile and used for a variety of bioprocesses. Key differences include their applications, design complexity, and control systems, with fermenters focused on fermentation and bioreactors supporting a broader range of biological processes.

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4 views7 pages

Lecture 3

Fermentors, or bioreactors, are sterilized vessels used for growing microorganisms under optimal conditions for commercial metabolite production, with various types including Continuous Stirred-Tank, Airlift, Packed Bed, Fluidised Bed, Membrane, and Bubble Column fermentors. The document distinguishes between fermenters, which are specifically designed for fermentation processes, and bioreactors, which are more versatile and used for a variety of bioprocesses. Key differences include their applications, design complexity, and control systems, with fermenters focused on fermentation and bioreactors supporting a broader range of biological processes.

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Lecture -3

What are Fermentors?


Fermentors, also known as bioreactors, are sterilised and
enclosed vessels that are used for the growth of microorganisms
under optimal conditions. The microorganisms can be grown in
large quantities to produce metabolites for commercial uses.
Fermentors are equipped with special components for heating,
mixing, and aeration. Its volume can be as big as 500,000 litres
for an industrial scale, or as small as 1 litre for laboratory uses.

Different Types of Fermentors


Continuous Stirred-Tank Fermentor
The continuous stirred-tank reactor (CSTR) is composed of a
vessel with pipes, pumps, valves, agitator, motor, shaft, and
impeller(s). The shaft is situated at the bottom of the tank, and
the number of impellers depends on the size of the bioreactor.
In this type of fermentor, a structure called sparger is found that
keeps adding air to the culture medium. It is a ring-like structure
with many holes. The sparger, along with the impellers,
distribute gas in the entire vessel. The impellers break down the
bubbles into smaller ones that are homogeneously distributed in
the bioreactor.

Airlift Fermentor
The airlift bioreactors contain a baffle or a draft tube in the
middle through which air is pumped into the vessel. There are
two types of airlift fermentors:
• Internal loop airlift bioreactor: It has a single central
draft tube that provides inner circulation channels.
• External loop airlift bioreactor: It contains external loops
that separate the liquids flowing into independent channels.
Packed Bed Fermentor
In a packed bed fermentor, a hollow tube or pipe is packed with
a biocatalyst. The bed is immobile in nature. The culture
medium flows through the biocatalyst, which produces the
metabolites continuously in the broth. These bioreactors are easy
to operate but are often blocked due to poor oxygen circulation.

Fluidised Bed Fermentor


In this type of reactor, a solid granular bed that is usually made
up of a biocatalyst is present. The fluid, that is, liquid or gas, is
passed through the solid bed at high speeds, such that the
suspended solid behaves like a fluid. This type of fermentor is
used for microbial flocs, immobilised cells, and enzymes.

Membrane Fermentor
Membrane bioreactors work in conjugation with ultrafiltration
and microfiltration. This type of fermentor is used for the
biological treatment of wastewater. There are two types of
membrane bioreactors:
• Submerged membrane bioreactor: In this type of
fermentor, the membrane is found inside the vessel
submerged in the wastewater.
• Side-stream membrane bioreactor: In this type of
fermentor, the membrane is found outside the reactor and
filtration by the membrane is an additional step in the
whole process.
Bubble Column Fermentor
A bubble column fermentor is equipped with a cylindrical
column that is filled with liquid, and gas is inserted into it from
the bottom. It is vertically arranged, such that the introduction of
gas from the bottom creates a turbulent stream and allows
optimum gas exchange. The sparger mixes the contents of the
vessel. The liquid flows either in a parallel direction or in a
counter-current direction.

Difference Between Fermenter & Bioreactor:


In the field of biotechnology, the
terms fermenter and bioreactor are frequently used but often
confused. Although both devices are used for the cultivation of
micro-organisms and cells, they have important differences in
design, applications, and technical specifications. Understanding
the difference between a fermenter and a bioreactor is crucial
for selecting the right equipment for the specific needs of the
process.
Fermenter
A fermenter is a piece of equipment specifically designed to
carry out fermentation processes, where microorganisms such as
bacteria, yeasts or fungi transform organic substances into
products such as alcohol, organic acids and gases. Fermenters are
common in the food and beverage industry, but also have
applications in the chemical and pharmaceutical industry.
Key features of a fermenter
Fermenters are used especially in the production of fermented
foods and beverages such as beer, wine, yoghurt and fermented
soy products. In the pharmaceutical industry, they are used to
produce antibiotics and other biotechnological products by
microbial fermentation.
• Specific application: Designed primarily for fermentation
processes.
• Control of conditions: Allows precise control of factors such
as temperature, pH and oxygen, essential for fermentation.
• Materials of construction: Generally made of stainless steel
to prevent contamination and facilitate cleaning.
• Process types: Handles both aerobic (with oxygen) and
anaerobic (without oxygen) processes.
Bioreactor
A bioreactor ⇀ is a more versatile piece of equipment used for a
variety of bioprocesses, not just fermentation. It is used in the
production of biotechnological products such as proteins,
vaccines, monoclonal antibodies and stem cells. Bioreactors can
grow animal and plant cells, as well as microorganisms.

Key features of a bioreactor


Bioreactors have different applications in the pharmaceutical
⇀ industry for the production of drugs, such as monoclonal
antibodies and vaccines. They are also used in the production of
biofuels, bioplastics, and in stem cell and gene therapy research.
• Versatility: Used for a wide range of processes, not just

fermentation.
• Scalability: It is very varied, ranging from small volumes in

laboratories to large volumes for industrial production.


• Advanced control: Includes precise monitoring and control

systems to optimise culture conditions, such as dissolved


oxygen, CO2, pH and temperature sensors.
• Diverse applications: Used in the pharmaceutical industry,

biofuel production, stem cell research, and more.


Main differences between a fermenter and a bioreactor
• Application: The fermenter is more focused on specific

fermentation processes, while the bioreactor is more versatile


and used in a variety of biological processes.
• Design and construction: Although both can be made of

similar materials, bioreactors tend to have more advanced and


complex control systems.
• Versatility: Bioreactors offer greater flexibility in terms of the

types of organisms and processes they can support.


• Process control: Bioreactors are equipped with advanced

control and monitoring technologies, allowing for accurate,


real-time management of culture conditions. Fermenters tend
to be less complex in comparison.
• Scalability: Both can be scaled up for industrial production,

but bioreactors have an advantage in the variety of scales and


process types they can handle, from research to commercial
production.
Frequently Asked Questions
Q1
What is the basic function of a fermentor?
The fermentor is an enclosed and sterilised vessel that provides
optimum growth conditions for the multiplication of
microorganisms.
Q2
What is the design of a fermentor?
The basic conventional design of a fermentor is a cylindrical
vessel with a top and bottom. A sparger is found at the bottom of
the vessel and is surrounded by a jacket.

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