How to choose a suitable bioreactor? A comprehensive guide from laboratory to industrialization!
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- Issue Time
- Jun 18,2025
Summary
In the fields of biopharmaceuticals, cell therapy, enzyme catalysis, etc., bioreactors are the core equipment for achieving efficient biotransformation.
Choosing a bioreactor requires consideration of "demand performance cost", which should not only meet current process requirements but also reserve space for technological upgrades.
一、Clarify core requirements: Starting from application scenarios
1. Select based on the characteristics of the biological system
According to cell type, mammalian cells are sensitive to shear forces and require the selection of air lift or wave reactors to reduce mechanical damage; Filamentous microorganisms (such as fungi) require a fixed bed reactor with low stirring intensity.
According to the type of reaction: anaerobic fermentation requires sealed tanks and gas recovery systems; Aerobic cultivation (such as antibody production) requires efficient dissolved oxygen transfer design, such as mixing tanks with microporous aerators.
2. Choose based on scale and production capacity
If it is in the laboratory stage, 2-50L glass or small disposable reactors are suitable for process development and support flexible parameter adjustment.
If it is industrial production, stainless steel reactors (made of 304/316L material) are suitable for stable mass production (such as vaccine production).
3. Choose according to the cultivation method
If it is a suspension culture, stirred tanks or wave reactors can be selected for suspension cells (such as hybridomas), with high mixing efficiency and easy scaling up.
If it is adherent culture, a fixed bed reactor can be selected to provide high surface area through a mesh carrier, supporting high-density adherent cell growth.
二、 Select based on key technical parameters
Consider selecting appropriate stirring blades for shear force control, and prioritize inclined blades or magnetic stirring for animal cell culture to avoid high shear damage from turbine blades; Microbial fermentation can use turbine blades to enhance dissolved oxygen transfer.
Consider fluid dynamics optimization by eliminating vortices through baffles or using a dual axis swing reactor (such as XRS 20) to improve mixing uniformity and reduce cell aggregation.
2. Consideration of Mass and Heat Transfer Efficiency
Considering precise dissolved oxygen (DO) control, Escherichia coli fermentation requires maintaining a dissolved oxygen saturation of 30% -50%, which can be improved by membrane aeration or oxygen enriched ventilation to enhance efficiency; Enzyme catalyzed reactions need to avoid excessive aeration that can cause protein denaturation.
Considering precise temperature and pH regulation, the jacketed heat exchange system (with an accuracy of ± 0.5 ℃) is combined with automatic acid-base replenishment to meet the pH requirements of mammalian cells at 7.0-7.4.
3. Considerations for Automation and Monitoring Systems
Consider sensor integration: real-time feedback from pH, DO, and temperature probes, combined with SCADA system to achieve parameter closed-loop control; A disposable reactor can use wireless sensors to simplify the verification process.
三、 Type and Material Selection
1. Comparison of mainstream reactor types
2. Material and Compliance
Stainless steel: 316L stainless steel requires ASME BPE certification and is suitable for long-term continuous production; The sealing element is made of PTFE material to prevent chemical corrosion.
四、 Case analysis
Production of Astaxanthin
Full process exposure of astaxanthin factory: from algae screening to ton level extraction, how to pour "red gold" from the laboratory into the factory?
Production of ergothionein
Due to a 90% drop in cost, the market for ergot sulfur is expected to exceed 100 billion yuan by 2026! Detailed understanding of the principles and advantages of biological fermentation method!
Production of biological microbial fertilizers
How important is bio fertilizer? Increase crop yield by 30%, reduce heavy metals by 50%, lose weight and increase efficiency, reduce medication and control harm!
