Fermentation in Biotechnology: Precision Flow Meter Applications

Modern pharmaceutical enterprises have increasingly stringent requirements for instrumentation and automation levels, which largely reflect the technical capabilities of these companies. This is especially true for fermentation processes, where precise control of various fluids entering and exiting bioreactors is crucial for the quality of biological products. Accurate flow control in stages such as bioreactor feeding, fermentation vessel feeding, reactor feeding, multi-medium mixing and transportation, and high-precision feeding is paramount.

Applications of Flow Meters in Biofermentation Processes

• Bioreactor Feeding: Bioreactors are the core equipment in the biofermentation process, controlling the growth environment and metabolic conditions for microorganisms. Flow meters are used to precisely control the flow of nutrient solutions within the reactor to ensure optimal growth conditions for microorganisms, thereby enhancing product quality and yield.

• Gas Distribution Systems: During biofermentation, various gas proportions need to be accurately adjusted based on different fermentation stages and microorganism requirements. Precise gas blending and flow control ensure the stability and reliability of the fermentation process.

• Fermentation Vessel Feeding: Fermentation tanks serve as the vessels for cultivating microorganisms in the biofermentation process. Flow meters are essential for accurately controlling the flow of culture medium to maintain a suitable environment within the tank, promoting the growth and metabolism of microorganisms.

Case Study: Erythromycin Production Line Fermentation Process

A biopharmaceutical company required precise monitoring of temperature, pressure, concentration, flow rate, velocity, pH, and liquid level during the erythromycin production line fermentation process. The raw materials included glucose solution, nitrogen source solution, culture medium solution, tryptophan solution, and glycerol solution. The common flow range for various solutions was 30L/h to 3m³/h, with a density of 1kg/m³ and pipe sizes ranging from DN15 to DN20.

To address the issue of foaming during bioengineering fermentation, a certain amount of fermentation defoamer needed to be added to the reactor.

The customer's requirements were precise measurement of various fluid raw materials to ensure dosage accuracy, continuous flow real-time control, and stable instrument performance that meets hygiene and cleanliness standards.

Understanding the customer's needs, we learned that ensuring the production process is not contaminated by other microorganisms is crucial. The customer's fermentation tanks and pipelines adopted SIP (online steam sterilization) methods for thorough cleaning and sterilization before inoculation to ensure in-situ sterilization. Therefore, the customer also needed to sterilize the flow meters while measuring specified raw materials.

To ensure stable instrument usage, we configured remote type electromagnetic flow meters with a precision of ±0.5% for measuring raw materials such as glucose solution, nitrogen source solution, and culture medium solution. Coriolis mass flow meters were chosen for measuring defoamers in the main pipeline, accompanied by temperature and pressure-related instruments.

The customer feedback has been positive, indicating that the selected flow meters align well with the pipeline design, ensuring precise measurement and efficient control of injected raw materials since the production line officially went into operation. This has helped the enterprise improve the stability and reliability of the biofermentation process, enhancing product quality and yield. Moreover, the flow meters are designed for easy maintenance, compact structure, and simple operation, facilitating routine maintenance and reducing usage costs.

Recommended Products for On-Site Applications

Coriolis Mass Flow Meters:

• Available in various wetted materials such as 304/316L for high cleanliness applications like food and pharmaceuticals.

• Dual micro-bend tube design for high accuracy, generally achieving ±0.10% or ±0.15% class.

• Direct measurement of fluid mass flow in closed pipelines and medium working density, doubling as a high-precision online densitometer.

• Compact structure or remote structure for easy installation and cost savings.

• Wide measurement range covering 0.035t/h to 40.5t/h.

• Various standard flange connection methods available.

• High stability with no need for frequent disassembly calibration.

• No need for straightening, filtering components, or special installation requirements.

• No obstructive elements and large flow passages reduce pressure loss, energy consumption, and waste.

Hygienic Electromagnetic Flow Meters:

• Suitable for conventional hygienic applications.

• High accuracy up to ±0.2%.

• Excellent measurement repeatability, up to 0.03%.

• Wide range of sizes from DN4 to DN2000.

• Almost no pressure loss and no obstructive flow components.

• Corrosion-resistant, suitable for most corrosive conductive liquids.

• Multiple signal outputs, including analog, frequency, current, and RS485 communication interfaces, with options for HART, PROFIBUS, FOUNDATION Fieldbus, and wireless communication methods like GPRS, NB, and 4G.

Temperature Transmitters:

• Simple assembly and easy replacement.

• Spring-loaded temperature sensing elements for good shock resistance.

• Large measurement range and high accuracy.

• High mechanical strength and good pressure resistance.

• Short response time.

The precision of flow meters in biofermentation processes is crucial for the quality and yield of biological products. By selecting the appropriate flow meters and maintaining them properly, enterprises can enhance the stability and reliability of their biofermentation processes, leading to improved product quality and increased output.