Joston Stainless Steel SUS316L / SUS304 Microbiology Jacket Temperature Control Fermentor Bio- Reactor with Mechanical Agitator System

• After-sales Service: Online Support/Visit Client′s Plant Site
• Warranty: 1 Year
• Type: Tank Reactor
• Material: Stainless Steel
• Capacity: >1000L
• Pressure: Positive
• Model NO.: BT
• Heating: Steam/Hot Water/Electrical
• Heat Transfer Structure: Jacketed
• Automatic Grade: Automatic
• Condition: New
• Function: Used for Various Kinds of Microbiology and Vaccine
• Key Selling Points: Aspetic Bioreactor, Vaccine Fermentation, Full Aut
• Transport Package: Export Standard Package
• Specification: 20L-20000L
• Trademark: JOSTON
• HS Code: 8479820090
• Production Capacity: 30 Sets/Month

Product Description

What is fermentor bio-reactor

Fermentor reactor is used for various kinds of microbiology fermentation ,our equipment adopt the top mechanical agitator system ,the speed can adjustable ,and the all parameters can control ,like the reactor temperature ,pressure PH data ,PO2 data ,foam destroyed etc .all the parameters can be recorded ,stored and printed from the control panel automatic .so it is excellent stability and convenient operation .
Fermentor bioreactor configuration

Body configuration: stainless steel SUS316L / SUS304 material; jacket temperature control, optimized diversion design; internal surface polishing, RA ≤ 0.4 μm; external surface polishing or matte treatment; large angle long strip mirror, pH electrode, do electrode, temperature electrode interface are complete; tank cover is equipped with flame inoculation port and feeding standby interface, etc.
Mixing system: top type mechanical mixing system; aseptic mechanical sealing system; DC mixing motor or AC motor; standard 2-layer flat impeller, one-stage high-efficiency defoaming paddle; optional inclined blade, curved blade, axial flow paddle, etc.; adjustable speed, digital set speed control.
Structural mode: floor type frame structure, saving space and convenient operation.
Ventilation system: deep ventilation, all stainless steel pipeline; glass rotameter display, pressure gauge display, manual valve to regulate the flow; German sartorius high-efficiency sterilization filter with stainless steel shell, filtering accuracy 0.01 μ m; external compressed air is required, equipped with high-quality water removal and pressure stabilizing device, to continuously and stably supply gas; optional mass flow controller to automatically control the air flow.
Tank pressure control: the top exhaust port is equipped with pointer type pressure gauge to display the tank pressure, and the stainless steel valve is manually adjusted; the optional inlet pressure transmitter and automatic regulating valve are equipped to realize automatic tank pressure control.
Temperature control: online detection, digital setting, automatic / manual control free switching; PT-100 temperature probe; electric heating temperature control and external cooling water automatic temperature control.
PH control: online detection, 2-way peristaltic pump automatically flows alkali or acid solution for adjustment; imported pH electrode can be sterilized by high temperature steam.
Dissolved oxygen (do): online detection, range 0-100% or 0-200%; imported do electrode, which can be sterilized by high temperature steam; it can be controlled in linkage with speed and ventilation.
Replenishment control: Standard 1-way peristaltic pump time proportional flow replenishment, flow replenishment cumulative display and record.
Defoaming mode: conductive foam electrode, automatic alarm for abnormal foam condition; standard 1 way peristaltic pump automatic / manual flow adding defoamer, cumulative volume display and record.
Control system: Siemens PLC controller real color plus touch screen, complete functions, stable operation.
Sterilization mode: in place sterilization, manual control.
Fermentor bioreactor Advantages
In place sterilization, safe and reliable, no transmission leakage risk; large viewing angle longitudinal mirror observation is clear; inoculation methods are various and reliable (standard flame inoculation port, differential pressure inoculation port and other forms are optional); floor type tank is beautiful and generous; operation and disassembly are easy; special specifications can be customized.

Fermentation tank:three  layers ,inside shell,material isSS316L,jacket material is SS304 ,outside with insulation layer cladding 2mm SS304 Sheet .top mounted propeller type agitator ( and  foam  destroyer ) ,.with the fittings of aspetic sampling valve ,bottom flush valve ,sight glass ,sight light ,PT sensor,pressure sensor,safety valve ,PH sensor ,DO sensor ,foam sensor ,level sensor,CIP spray ball ,SIP nozzle ,air purge etc ,seed culture and harvest system etc . contact product product material is SS316L ,non-contact part is SS304 ,inside mirror polish is Ra<0.4um ,outside surface polish is Ra<0.6um.
Air filter:single stage filter ,filter micropore is 0.01μm,can online SIP .
Temperature PID control:use the steam to heating and chiller to recycle cooling to make the temperature PID control .
Flow meter:use the electronic flow meter to control the inlet air online
Sampling valve:SS316L material, aspetic type ,can be sterilizer online
PH data control:With intelligent PID control, the pH control performance is very good. It is equipped with special pH electrode for fermentation. The control range is 2-12ph, the display range is 0-14ph, the control precision is ± 0.02PH, and the resolution is 0.01ph;
P02 data control:With the intelligent PID control, The system is equipped with special do electrode for fermentation, control range: 0-100%, display range: 0-200%, control precision: ± 5%, resolution: 0.1%;
SIP system:It has perfect and reliable tank sterilization system, sterilization temperature: 100-130 ºC;
we use the peristaltic pumps to feed the raw material ,acid ,alkali ,foam destroyer solution etc. feeding volume can be measured;Specially designed feeding needle is equipped to ensure safe operation of feeding.
Control system                                   
1.PLC/HMI:he analysis and control system of biological fermentation process is composed of field controller (special software + Siemens PLC-S7200 ,HMI is Siemens-TP1200), sensors and actuators.Features of control system: the field controller is based on S7-200 series programmable controller of Siemens as the core and special software. It adopts multi-level expansion, strong function, safety and stability, and is easy to maintain and upgrade. The industrial Siemens man-machine interface is adopted in the field controller The intelligent PID control is adopted in the control aspect, which has stable control, high control precision and parameter self-tuning control algorithm.
2.Detection and control function:At the same time, it can detect and control the mixing speed, temperature the tank, pH value, DO2 value, feeding, acid and alkali, defoaming, etc;
3.PID regulation:Each parameter has PID adjustment process display, such as set val real-time value, PID set value, upper and lower limit value;
4.alarm function:it can set the upper and lower limits of temperature, speed, pH value and
DO2 value, and has the function of over limit alarm;
5.Control switching:The speed, temperature, pH value, DO2 value and feeding can be set to automatic or manual ;
6.Timing and quantitative feeding:There is a perfect feeding system, the peristaltic pump can be fixed time and quantitative feeding, feeding can be measured, can be displayed in curve;
7.Defoaming and rehydration:It has the function of over liquid level alarm and automatic liqu replenishment, and has the function of over foam alarm and automat addition of defoamer;
8.Associated control:The method of changing the speed can improve the concentration of dissolv oxygen;The correlation control of feeding and pH; the correlation control feeding and dissolved oxygen.
9.Sterilization function:Manual control, the sterilization method includes jacket heating, and stea sterilization in the tank; or no steam in the tank, only relying on jacket heati
sterilization, sterilization temperature: 100-130 ºC;
10.Data display,recording and storage:The system has real-time display, data recording, data storage, data analy (histogram, curve).Line chart and Batch Report) output printing, password manageme exception analysis and alarm functions;
11.Setting and calibration:The parameters of each detection and control loop can be manually set and modified online on the screen, and the temperature, pH, DO2 sensors can be adjusted, and the flow rate of each peristaltic pump can be calibrated;
12.Diagnosis and protection:The system has the ability of self-adaptive and self diagnosis, and can automatically alarm and protect the abnormal situation according to the customer's settings.
13.Check the alarm accident:All alarm accidents can be recorded and consulted;
14.Password protection:The operation has password protection function, and the password is divided into operator and administrator level passwords;
15.Control switching:With automatic control and manual control switching.
 

1. Main technical parameters of fermentation system:

 

NO	ITEM	Control range and precision
1	Agitator control	Speed adjust by VFD control,the speed range: 0-350rpm; control accuracy: ± 0.5%, resolution: 1rpm. It adopts direct mechanical upper mixing system, special single face mechanical seal, servo motor, variable frequency driver regulation, automatic speed control. Blades: high performance agitator for fermentation, two layers of six flat blades, one layer of inclined blades and one layer of defoaming impeller, The controller can realize: speed and do associated control, curve analysis, batch report analysis, high and low alarm data setting.
2	Temperature control	PID automatic control, hot water heating by electrical circultion heating, chiller cooling with circulation system. Control range: cooling temperature + 6-50 ºC , control accuracy: ± 0.2 ºC, resolution: 0.1 ºC; Sterilization temperature: 100-130 ºC , sterilization time: 0-60min; te which can realize sequence control: curve analysis, report display, data processing, abnormal alarm, process sequence control (set according to fermentation time section, automatic variable control), etc
3	pH	PID automatic control, peristaltic pump control, one-way or two-way control can be selected; It is not easy to produce fluctuation. 2sets  peristaltic  pump  switch control flow, acid and alkali, automatic control. The electrode can be sterilized repeatedly, and the calibration function is completely calibrated by the system software. Display range: 0.00-14.00 ± 0.01, automatic control range: 2.00-12.00 ± 0.2 Online detection, automatic alarm, with peristaltic pump automatically add acid and alkali 3. PID intelligent control. The controller can realize: pH value curve analysis, acid and alkali addition curve analysis, batch report analysis, sequence control, etc. Control range: 2-12ph, control precision: ± 0.02PH, resolution: 0.01ph
4	DO2	PID automatic control, air through the flowmeter control; can be associated with parameters such as speed control. Measurement range: 1 ~ 200%, control accuracy: ± 5%, resolution: 1%. It can realize sequence control: curve analysis, report display, data processing, abnormal alarm, sequence control, etc
5	Pressure display	Automatic / manual control, remote transmission / pressure gauge display;
6	Air inlet	Manual valve control, flow meter display;

1. Main components of fermentor:

 

NO	ITEM	Description	QTY
1	Fermenter	Spec as the production drawing
2	Sampling valve	QRF
3	Mechanical seal	Single face mechanical seal
4	Motor	Servo type motor
5	PLC/HMI	PLC:S7-200 HMI:TP1200
6	VFD	Control the speed	1
7	Flow meter	Flow capacity	1
8	Micropore filter	0.01μm	2
9	Feeding peristaltic pump	BIOQR	1
10	Foam destroyer peristaltic pump	BIOQR	1
11	Acid peristaltic pump	BIOQR	1
12	Alkali peristaltic pump	BIOQR	1
13	recycle pump	Cooling water recycle for the jacket	1
14	DO2 Sensor	Mettler Toledo	1
15	DO2 cable	Mettler Toledo	1
16	PH sensor	Mettler Toledo	1
17	PH cable	Mettler Toledo	1
18	Foam sensor		1
19	Temperature sensor	PT100	2
20	Pressure sensor	-0.1-0.5MPa	1
21	Bottom flush valve	SS316L ,aspetic type	1
22	Sight glass/light	12V	1
23	Trap valve		1
24	Safety valve		2
25	Pressure gauge		2
26	Diaphragm valve		1lot
27	Pipe fittings		1lot

 

1. Spare Parts for     fermentor:

 

NO	ITEM	Spec	Qty	Remark
1	High temperature resistant feeding bottle (glass)		3pcs
2	High temperature resistant feeding bottle (glass)		1pcs
3	Feeder bottle accessories		4sets
4	Special feeding pin (with coat)		1pcs
5	Special feeding pin (with coat)		1pcs
6	High quality sanitary grade silicone hose		16M
7	High quality sanitary grade silicone hose		16M
8	Simple tools and toolbox		1pcs
9	Spare seal O-ring		10pcs
10	Special silicone plug		20pcs
11	Sterilization filter 0.1 μ m		4pcs

Technical description
 

Item	Technology specification
Working volume L	5-6000L
material	Contact product is SS316L ,non-contact part is SS004
Surface finish	Inside surface is mirror polish Ra:0.3-0.5um Outside surface is mat polish Ra<0.8um
Working pressure	Inside shell is 0.2MPa; jacket is 0.3MPa
Agitation	1).Top mechanical agitator with two layers six blade impeller ,one is for foam destroyer ,gear motor use SEW brand 2).Speed is 0-400RPM ( adjustable )
Equipment of tank	1) .using alcohol flame inoculation 2) Sterile type sampling valve and bottom flush valve 3) PH sensor ,PO2 sensor ,foam sensor ,flow meter ,temperature sensor ,Pressure sensor ,level sensor ,sight glass ,sight light etc
construction	Fermentation reactor tank with completely pipeline and PLC/HMI control panel

Product drawings
SERVICE

We have established some overseas agent office to make the after-sales serivce already ,so it can will be service client in fast response .also in our headquarter service team ,there is a expert team which can support client in 7*24 hours .
1. Customer inquiry and consultation (URS documents)
2. Confirmation of treatment plan (DQ documents &PID Drawing)
3.Quotation offer with the technolgy document (Quotation PI )
4.Engineering and Manufacturing (Prodcution &Quality inspection )
5. Product inspection (FAT documents)
6. Delivery arrangement and loading work (full set Shipment documents)
7. After-sales service (OQ,PQ ,SAT documents)


FAQ

1.What about your factory?
Our factory is located in Wenzhou city ,Zhejiang Province and have more than 15 years experience on machinery making.

2.How will your company  control the equipment quality ?
We have a qualified expert team ,we will inspect every production proceed .also Machines will be tested in our plant before shipment .

3.How long the warranty will be?
We provide 1 years warranty for the machine running ,but we will afford whole -life service for the machine .

4.Which kind payment do your company do now ?
We accept Western Union, T/T ,D/P,D/C and irrevocable L/C payable etc.

5.Can  we  become  your distributor in our country?
Yes, we very welcome you! More details will be discussed if you are interested in being our agent.

6.Why we choose "JOSTON "?
1. We enhance the reliability of product's quality and working life . 
2. We decrease the consumption cost of the product in the ruuning. 
3. We improve research personnel's ability to deliver a creative design; 
4. We use leading technologies in our product development and innovation, and thereby increase the competitive advantage of products.

7.Do you supply installation equipment in oversea?
Yes, if need, we can  send our  engineer to your plant to help you do installation and commission.

8.How can we know the order production status ?
We will arrange the person to take photo or video during manufacturing in every  week to make you to know the production status.When goods are finished,we will take  detailed photos or video for your checking ,after approve ,then we will arrange shipment .also you can arrange FAT in our plant when the goods is ready here

9.what is kind service do you offer before making order ?
1.according to your company URS ,we will make the design  drawing accoridingly.
2.after your company approved drawing ,we will make quotation.
3. final we make agreement on payment terms ,delivery time ,package ,shipment etc.

10.how about your company after-sale serivce ?
1. We provide long-term after-sale service. 
2. we can do installation and commission for the equipment in your plant if necessary .
3. Meanwhile, you can call or e-mail us to consult on any relevant question since we have a special line for after-sale service. Alternatively, you can communicate on-line with us to solve any problem.