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Fully Automatic Fermenter

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Overview

A fully automatic fermenter is a fermentation tank that incorporates full automation control throughout the entire system. It is safe, reliable, stable, and highly efficient. As an integrated system, it primarily consists of a seed tank, a fermentation tank, a feeding tank, a sterile air filtration system, an automatic fermentation process control system, auxiliary equipment, and a pipeline valve system. It represents an engineering solution that integrates both mechanical and control technologies.

Main Control Points

No. Name Performance Requirements and Technical Specifications
1 Temperature Control System 1. Measurement Range: 0–150°C
2. Control Range: Normal temperature to +65°C for the water tank
3. Control Accuracy: ±0.2°C
4. Resolution: 0.1°C
5. Control Functions: On-line temperature detection, PID intelligent control with configurable setpoints according to fermentation process requirements
6. Component Selection: Japanese imported PT100 platinum resistance temperature sensor, SUS304 stainless steel electrode sheath, stainless steel electric heating tube, SUS304 stainless steel constant temperature water tank, hot water circulation pump control
7. Features:
A) Equipped with hot water tank for Circulating Temperature Control，saving energy
B) PID intelligent control system ensures rapid and energy-efficient temperature control
C) jacket remains at zero pressure duringCirculating Temperature Control，eliminating the need for external safety valves for enhanced safety and reliability
8. Alarm function for temperature exceeding upper/lower limits
9. Software Functions: Data curve graph, data report, manual/automatic temperature control modes
Production-scale fermenter constant temperature hot water tank with independent temperature control, including water inlet, return port, overflow port, drain port. Material: SUS304 stainless steel with surface polishing treatment. (One large constant temperature hot water tank shared by three fermenters)
No. Name Performance Requirements and Technical Specifications
2 pH On-line Detection and Control System 1. Control Mode: Fully automatic control with configurable pH setpoints
2. Display Range: 0–14 pH
3. Control Range: 2–12 pH
4. Resolution: 0.01 pH
5. Control Accuracy: ±0.03 pH
6. Control Functions: On-line pH detection, PID intelligent control
7. Component Selection: Swiss imported Mettler glass gel pH electrode for detection, capable of in-situ high-temperature sterilization (121°C for 30 minutes). On-line pluggable electrode sheath and transmitter, connected with Mettler original double-shielded signal transmission line to ensure precise pH control
8. Actuator: Microcomputer intelligent PID control peristaltic pump or solenoid valve for automatic acid/alkali dosing to maintain pH within the set range, with manual/auto control modes
9. pH upper/lower limit alarm function
10. Software Functions: Data curve graph, data report, manual/auto pH control
11. Electrode Length: 120 mm; Electrode Outer Diameter: 12 mm; Installation Size: 25 mm
No. Name Performance Requirements and Technical Specifications
3 DO Detection System 1. Detection Mode: Automatic detection
2. Display Range: 0–100% or 0–150%
3. Display Accuracy: ±0.1%
4. Control Functions: On-line DO value detection
5. Component Selection: Swiss imported Mettler polarographic dissolved oxygen electrode for detection, capable of in-situ high-temperature sterilization (121°C for 30 minutes). Equipped with stainless steel electrode sheath and transmitter, connected to PLC via original Mettler double-shielded signal transmission line to ensure precise DO display
6. System with DO abnormality alarm function
7. Electrode Length: 120 mm; Electrode Outer Diameter: 12 mm; Installation Size: 25 mm
No. Name Performance Requirements and Technical Specifications
4 Pressure and Flow Control System 1. φ60–φ100 surface axial/radial stainless steel pressure gauges indicate pipeline, tank, and jacket pressure. Tank pressure controlled by manual diaphragm valve with range: 0–0.4 MPa.
2. Gas inlet flow controlled by glass rotameter with manual diaphragm valve.
3. Check valve installed in pipeline to prevent material backflow and filter contamination.
5 Feeding System 1. Actuator: Constant-flow peristaltic pump or solenoid valve for feeding.
2. Control Mode: Automatic material feeding with manual/auto control modes.
6 Defoaming System 1. Control Mode: Fully automatic control.
2. Control Accuracy: 10–100,000 Ω.
3. Control Functions: Foam abnormality alarm and automatic intermittent treatment.
4. Actuator: Foam sensor detection with microcomputer-controlled peristaltic pump or solenoid valve for defoamer dosing.
5. Control Mode: Manual/auto control modes.
7 Rotation Speed Control System Siemens frequency converter for speed regulation: 50–400 rpm ±1% (variable frequency speed control).
Fermenter-specific: Siemens frequency converter, 50–350 rpm ±1%, stepless variable frequency speed control.
No. Name Performance Requirements and Technical Specifications
8 Lower-level Fermentation Process Control System 1. 10.4″ wide-screen color LCD touchscreen with PLC programmable control. User-friendly HMI (Human-Machine Interface). One controller can simultaneously monitor and control corresponding parameters of multiple seed tanks and fermenters.
2. The bioprocess control system consists of a field controller, fermentation process control software, sensors, and actuators. The field controller, centered on a programmable logic controller, uses multi-level expansion with sufficient A/D conversion channels, D/A conversion channels, and digital I/O ports. It features an industrial-grade HMI, enabling independent operation without a host computer, enhancing system reliability.
3. The software control system employs an advanced fuzzy control architecture, including a lower-level controller for field signal acquisition/transformation and software. All control loops use intelligent PID with high precision and self-tuning algorithms.
4. The on-site HMI uses a high-sensitivity LCD touchscreen with a fully Chinese interface, supporting digital setting, rapid calibration, data storage, over-limit alarms, and password protection. The monitoring software is developed based on a well-known domestic configuration software, featuring an aesthetic interface, comprehensive functions, flexible operation, and stable performance. The controller is equipped with a USB port for data export to external printers.
Control System Functional Description 1. Monitors and controls fermenter agitation speed, temperature, and pH.
2. Parameters of each control loop are manually configurable on-screen with password protection.
3. PID control mode with manual/auto bumpless transfer, adaptable to various control elements and performance requirements.
4. Real-time data display and logging in trend graphs and charts.
5. Upper/lower limit alarms for all loops.
6. Power failure protection with data backup.
7. Visualized operation via HMI.
8. Built-in clock for batch date and runtime tracking.
9. Configurable alarm suppression (temporary/permanent).
10. Acid/alkali addition visualization with curve-based pH profile control.
11. Temperature profile control with time-segmented curve setting.
12. Feeding process visualization with cumulative volume display.
13. Defoaming function with foam level recording and process visualization.

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