A fermenter is an apparatus that maintains optimal conditions for the growth of

microorganisms, used in large scale fermentation and in the commercial production of an

array of products such as antiboitics hormones alcohol etc .The main function of the
fermenter is to provide a controlled environment  for the growth of a pure culture or of a
defined mixture of microorganisms or animal cell to obtain the desired product. The first
true large scale fermenter aerobic fermenter were used in Central Europe in the 1930s for the
production of compresed yeast. The fermentation process is carried out in a strict aseptic
condition. So while constructing of a fermenter, selection of materials is important. The
material should be capable withstand repeated steam sterilization conditions.      

Different parts of fermenter:

1) Fermenter Vessel:

A suitable vessel is used to carry out the whole fermentation process. The vessel is capable of
being operated aseptically and meet the containment requirements. The vesse is designed in
such a way that it requires minimal labour operation and maintainence. It has smooth
internal surfaces and a similar geometry. The cheapest material which enables satisfactory
results is used. Depending upon the fermentation process two types of vessels are used. For
small scale fermenration, glass vessels are used and for industrial scale stainless steel vessels
are used.

Glass vessel:          

Glass vessels are smooth which makes it non toxic, corrosion proof. It also makes it easy to
examine the interior of the vessel. The large vessels are usually borosilicate battery jars with
a round or flat bottom and a top flanged carrying plate. These vessels requires autoclaved
sterilization. The diameter of glass fermenter is nearly 60cm.

Stainless steel vessel:

 Stainless steel is the most satisfactory material for large scale fermentations. These vessels
can be sterilized in situ and hence have the capability to withstand pressure and corrosion.
The corrosion resistance of stainless steel is depends upon the thin hydrous film on the
surface of the metal. This film is stabilized by chromium and is continuous, non porous,
insoluble and self heating. Corrosion resistance can be improved by tungsten, silicone and
other elements. 

2) Heating and cooling apparatus:

During fermentation process, heat is generated due to microbial activity and mechanical

agitation. The heat generated by both these processes should be ideal. To maintain this
temperature, heat is to be either added to or removed from the system. Heat is generally
provided by placing the fermenter in a thermostatically controlled bath, or by use of internal
coils. To remove excess heat from the system, silicone jackets are used. They consists of
double silicone mat with heating wires between the mats. Once a certain size is exceeded, the
surface area covered by the jacket becomes too small to remove heat, in such case cold water
is circulated on the internal coils to maintain the accurate temperature.

3) Sealing assembly:

 Sealing assembly provides most satisfactory sealing to the stirrer shaft, which is required to
provide agitation. This assembly can be operated aseptically for long periods. Three
types seal assembly are used:

Packed gland seal: The shaft is sealed by several layers of packing rings of asbestos, pressed
against the shaft by a gland. The packing rings are regularly replaced and checked to prevent
unsatisfactory heat penetration.

Mechanical seal: The seal is consists of two parts, the stationary part in the bearing and the
other rotating on the shaft. The two components are pressed together by springs. Stem
condensate are used to lubricate and cool seals during operation.

Magnetic drives: It consists of two magnets, one driving and another driven. The driving
magnet is held in bearing on the outside of head plate and connected to the drive shaft. The
internal driven magnet is placed on one end of the impeller shaft and held in bearings on the
inner surface of the headplate.

4) Baffles:

 Baffles are metal strips nearly one tenth of the vessel diameter and attached radially tp the
wall. They are incorporated into agitated vessels of all sizes to prevent vortex and to improve
aeration capacity. Baffles maintain a gap between them and the vessel wall to enable
scouring action thus minimising microbial growth on the walls of the fermenter.

5) Impeller:

Impeller is used for agitation. Agitation is required to ensure that a uniform suspension of
microbial cells is acheived in an homogeneous nutrient medium. The impeller achieves a
number of mixing objectives like suspension of solid particles, bulk fluid and gas phase
mixing etc. Impellers are classified as:

Disc turbines: It consists of a disc with a series of rectangular vanes. the vanned disc disc
again has a series of rectangular vanes attached vertically on the underside. Air from the
sparger hits underside of the disc and is displaced towards the vanes where the air bubbles
are broken up into smaller bubbles.

Variable pitch open turbine: It also contains vanned disc, the vanes of which are attached to
the blades of a marine propeller on the agitator shaft. The air bubbles in this turbine do not
hit any surface before dispersion by vanes or blades.  

6) Sparger:

Sparger is used for aeration. The purpose of aeration is to provide sufficient oxygen to the
microoraganisms for metabolic requirements. Sparger introduces air into liquid in the
fermenter. Three types of sparger are used:

Porous sparger: It is used on the laboratory scale. It is made up of sintered glass or ceramics
and is used in non agitated vessel.

Nozzle sparger: It is a single open or partially closed pipe which provides stem to the air
bubbles. The single nozzle sparger are mostly used because they causes a lower pressure and
does not get blocked.

Combined sparger - agitator: It introduced air thriugh a hollow agitator shaft and emitting it
from the holes drilled in the disc and connected to the base of the main shaft. It gives good
aeration in a baffled vessel when the agitator is operated at a range of rpm.

7) Feed ports:

Feed ports are slicone tubes connected to the nutrient reservoir. They are used to add
nutrients and acid/alkali in the fermenter. They are sterilized in situ with stem after
connection has been completed and before any additions are made.

8) Foam control:

Foam minimization is important in fermentation. Excessive foam results in wetting of filters

thus resulting in contamination. A foam sensing and controll unit is used to control foam. A
probe is inserted through the top plate of the fermenter. It is set at a defined level above the
broth surface. when the foam rises and touches the probe tip, a current is passed through the
circuit of the probe. The current actuates the pump and an antifoam is released within
seconds.
9) Valves:

       Valves are required to controll the flow of gases and liquids in a variety of way. Five types
of valves are used.

Globe valves: They are suotable for general purposes on stem or a water line for use when
fully opened or fully closed. They do not regulate flow.

Butterfly valves: They are used in large diameter pipes operating under low pressure. They
are not suitable for aseptic operation.

Ball valves: They are suitable for aseptic condition. the can handle mycelial broths and can
be operated under high temperature.

Diaphragm valves: They are used for flow regulation and for stem services within pressure
limits.

Safety valves:

Safety valve is incorporated in every air or stem vessel and pipe layout which is subjected to
work under pressure. These valves ensures that the pressure never exceeds the safe upper
limit of the specified value. In simple safety valves, a spindle islifted from its seating against
the pressure of gas. Once the pressure falls below the value set by the spring, the spindle
return to its fermenter. 

A fermenter is an apparatus that maintains optimal conditions for the growth of

microorganisms.
The main function of the fermenter is to provide a controlled environment for the growth of
a pure culture or of a defined mixture of microorganisms or animal cell to obtain the desired
product.
Different parts of fermenter:-

1) Fermenter Vessel:

A suitable vessel is used to carry out the whole fermentation process. The vessel is capable of
being operated aseptically and meet the containment requirements.

Glass vessel:

Glass vessels are smooth which makes it non toxic, corrosion proof. It also makes it easy to
examine the interior of the vessel.

Stainless steel vessel:

Stainless steel is the most satisfactory material for large scale fermentations. These vessels
can be sterilized in situ and hence have the capability to withstand pressure and corrosion.

2) Heating and cooling apparatus:

During fermentation process, heat is generated due to microbial activity and mechanical
agitation.
Heat is generally provided by placing the fermenter in a thermostatically controlled bath, or
by use of internal coils. To remove excess heat from the system, silicone jackets are used.

3) Sealing assembly:
Sealing assembly provides most satisfactory sealing to the stirrer shaft, which is required to
provide agitation.

Three types seal assembly are used:

Packed gland seal: The shaft is sealed by several layers of packing rings of asbestos, pressed
against the shaft by a gland.

Mechanical seal: The seal is consists of two parts, the stationary part in the bearing and the
other rotating on the shaft. The two components are pressed together by springs.

Magnetic drives: It consists of two magnets, one driving and another driven.

4) Baffles:
Baffles are metal strips nearly one tenth of the vessel diameter and attached radially tp the
wall. They are incorporated into agitated vessels of all sizes to prevent vortex and to improve
aeration capacity.

5) Impeller:
Impeller is used for agitation. Agitation is required to ensure that a uniform suspension of
microbial cells is acheived in an homogeneous nutrient medium.

6) Sparger;
Sparger is used for aeration. The purpose of aeration is to provide sufficient oxygen to the
microoraganisms for metabolic requirements.

7) Feed ports:
Feed ports are slicone tubes connected to the nutrient reservoir. They are used to add
nutrients and acid/alkali in the fermenter

8) Foam control:
Foam minimization is important in fermentation. Excessive foam results in wetting of filters
thus resulting in contamination. A foam sensing and controll unit is used to control foam.

9) Valves:
Valves are required to controll the flow of gases and liquids in a variety of way. Five types of
valves are used.

Globe valves: They are suotable for general purposes on stem or a water line for use when
fully opened or fully closed. They do not regulate flow.

Butterfly valves: They are used in large diameter pipes operating under low pressure. They
are not suitable for aseptic operation.

Ball valves: They are suitable for aseptic condition. the can handle mycelial broths and can
be operated under high temperature.

Diaphragm valves: They are used for flow regulation and for stem services within pressure
limits.

Safety valves:
Safety valve is incorporated in every air or stem vessel and pipe layout which is subjected to
work under pressure. These valves ensures that the pressure never exceeds the safe upper
limit of the specified value.http://www.oppapers.com/essays/Fermenter/446669