Ministry of Industry and Information Technology+Chinese Academy of Sciences! High performance bioreactors are unveiled, leading the way in solving the bottleneck problem of biomanufacturing (interpretation of microbial parallel bioreactors)

Through the national ranking mechanism, scenario verification, and ecological construction, domestic equipment is expected to achieve a leap from "usable" to "user-friendly" by 2027, providing a Chinese solution for global biomanufacturing.

Microbial parallel bioreactor is an "intelligent breeding factory" in the field of biomanufacturing. Its core value lies in achieving precise reproduction of process parameters through multivariable synchronous control, solving industrial pain points such as low efficiency in traditional shake bottle screening (flux<24 holes), data dispersion (system error>20%), and high failure rate in process amplification (pilot scale to production parameter deviation>30%).

The unveiling task this time focuses on 7 major technical modules, whose underlying logic is a three-dimensional breakthrough through hardware accuracy improvement, software algorithm optimization, and data closed-loop management, to build a "digital twin base" for domestic biomanufacturing.

Background parallelism: It is required to ensure the high consistency of physical parameters (such as stirring blade diameter deviation<0.5%) between the 12 reactors through processing technology control (such as CNC machining accuracy ≤± 0.01mm), which is the basis for achieving reliability of high-throughput experimental data.

At present, the background parallelism error of domestically produced equipment is generally between 8-10%, mainly constrained by precision machining processes (such as laser welding deformation control) and material consistency (such as intergranular corrosion differences in stainless steel 316L).

Micro feeding: A feeding system based on electromagnetic drive and mass flow meter needs to be developed to achieve continuous feeding at the μ L level (accuracy ≤± 0.5%) and solve the problem of uneven feeding caused by pulse effects in traditional peristaltic pumps.

Industrial control unit: Requires integration of DoE (experimental design) and machine learning algorithms, supporting user-defined reaction processes such as pH step control and dissolved oxygen pulse regulation.

Intelligent operating system: requires iterative optimization control capability, such as dynamically adjusting feeding strategy through online monitoring of OUR (oxygen uptake rate), to achieve a target product (such as PHA) yield increase of more than 20%.

PAT integration capability: It is necessary to integrate third-party tools such as Raman spectroscopy and mass spectrometry through autonomous and controllable communication protocols (such as OPCUA) to achieve real-time data collection and feedback control.

Data standard: It is necessary to follow the ISA-95 standard to establish a bioreactor data model and solve the problem of incompatible data formats between different devices. Currently, domestic enterprises mostly use proprietary protocols from Siemens and ABB, which result in high data exchange costs.

1. If the system error is less than 5%, the parallelism between devices can be determined by the difference in OUR, CER (carbon dioxide release rate), or KLa (oxygen transfer coefficient).

This requires the design of stirring blades (such as Rushton turbine diameter deviation<0.1mm), ventilation distribution (such as pore size consistency<1% for microporous aerators), and sensor accuracy (such as dissolved oxygen electrode response time<5s) to reach the international top level.

Full process exposure of astaxanthin factory: from algae screening to ton level extraction, how to pour "red gold" from the laboratory into the factory?

KLa ≥ 800h ⁻¹ KLa is a core indicator for measuring the oxygen supply capacity of a reactor, and a level of 800h ⁻¹ can support high-density fermentation of Escherichia coli (OD600>100).

This requires collaborative optimization of agitation and aeration, such as using a combination of double-layer inclined blade impellers and microporous aeration to improve gas-liquid mass transfer efficiency while maintaining low shear forces (shear rate<500s ⁻¹).

At present, the KLa of domestic equipment is generally between 500-600h ⁻¹, mainly limited by aerator materials (such as imported PTFE membranes with porosity>80%, domestic membranes only 65%) and fluid simulation algorithms.

Sterilization air culture bacterial infection rate ≤ 1%: Dynamic pressure pulse sterilization technology needs to be developed to eliminate sterilization dead corners by alternating pressure (0.1-0.3 MPa) and vacuum (-0.08 MPa).

Automatic Cleaning (CIP): The accompanying 32-bit cleaning device needs to complete the entire process within 30 minutes, involving multi nozzle matrix design (such as rotating nozzle coverage angle>270 °) and cleaning solution formula optimization (such as NaOH concentration gradient control).