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ESSENTIAL GUIDE TO FERMENTATION
IN BIOREACTORSWhat is a Bioreactor?
Fermentation for Nutrient-Rich and FlavorIntense Foods
Fermentation is a metabolic process that uses microorganisms, such as bacteria and yeast, to transform organic
substances into various chemical compounds. These compounds can vary in complexity, from simple molecules
like ethanol derived from sugar to intricate molecules that serve as the foundation for advanced pharmaceuticals
or other high-value products through metabolic engineering.
The fermentation process is conducted in specialized vessels called bioreactors or fermenters, depending on
the specific application and the organisms involved. Although both bioreactors and fermenters are utilized
in biotechnology processes, there is a notable distinction between them. Bioreactors are used to cultivate
mammalian and insect cells, whereas fermenters are used to cultivate microorganisms like bacteria, fungi(primarily yeast), or algae.

A bioreactor is an advanced equipment crucial

As a 3 in 1 bioreactor, fermenter andfor modern biotechnological innovation. These

photobioreactor, the IKA HABITAT offers

precision devices, equipped with the latest

outstanding features and benefits oversensors and control systems, are designed to

traditional bioreactors in biological processes

finely tune environmental parameters such asthat optimize the quality of the final producttemperature, pH, and oxygen levels, creatingand enable its scalability. In certain applications,

ideal conditions for the cultivation of cells orthese vessels are indispensable, enabling

microorganisms.

contemporary biotechnological advancements
beyond the reach of traditional methods.

GlucosePyruvic acid

Microorganism

Fermentation
Product

Propionibacterium

CO2
Propionic acid

Swiss cheese

Aspergillus
lactobacillus
Streptococcus

Saccharomyces

Clostridium

Escherichia
Acetobacter

Lactic acid

CO2 , Ethanol

AcetoneIsopropanol

Acetic acid

Yoghurt, Soy sauce,
Cheddar cheese

Wine, beer

Nail polish remover
Rubbing alcohol

VinegarFigure legend: Examples of products produced by fermentation

Essential Guide to Fermentation in Bioreactors | 2

Essential Guide to Fermentation in Bioreactors | 3

/// Difference between Bioreactors
and Fermenters/// Importance of a Bioreactor forFermentation

The main differences in the technical design between bioreactors and fermenters lie inthe mixing and aeration processes, as well as the height to diameter ratio (H/D). Thesedesign disparities significantly impact the cultivation of microorganisms and cells.

Bioreactors can bring a level of precision to fermentation processes that traditional
methods cannot match, allowing for greater control over the environment in whichmicroorganisms grow and produce biochemical products. Unlike traditional fermentation
pots or open-air systems, which are subject to fluctuating external conditions,
fermentation-capable bioreactors maintain a carefully monitored and controlled space.
They consistently regulate temperature, pH, oxygen levels, and nutrient flows to optimize
the performance of the microbes.

For example, the mixing environment for microorganism cultivation is typically intensive,characterized by the effective dispersion of gas bubbles and high aeration rates. In
contrast, cell cultures require gentle mixing with a lower aeration rate to maintain their
viability and growth.
Furthermore, the optimal H/D ratio of the vessel differs between microorganism
cultivation and cell cultures. For microorganism cultivation, an H/D ratio of 3:1 isconsidered ideal, while cell cultures thrive best with an H/D ratio of 2:1. Another key
difference is that cell cultures can grow either in suspension or adherently, whereas
microorganisms always grow in suspension.

The precision offered by these bioreactors during fermentation enhances product quality.
The environments can be finely tuned to meet the specific demands of various processes,
providing high-standard outputs for products ranging from alcoholic beverages tocomplex pharmaceuticals. Production uniformity and reliability that may be difficult toachieve with traditional equipment are more attainable in the controlled confines of abioreactor.
Furthermore, the scalability inherent in bioreactor systems allows for a more managed
transition from benchtop experiments to industrial-scale production. The scaling process
in bioreactors is generally more straightforward and replicable than in basic fermentation
vessels, which may not consistently replicate small-scale conditions at larger volumes.
Coupled with automation, bioreactors can substantially improve process efficiency while
preserving the integrity of the product regardless of the scale.
Bioreactors are also designed to minimize the risk of contamination—a criticalconsideration, especially when the products are for sensitive industries such as food andpharmaceuticals. While traditional practices may be adequate for some fermentation
purposes, the stringent sterility requirements for these sectors are more reliably met
within the highly controlled environment of a bioreactor. end product is high in quality
and meets the necessary safety standards.

Essential Guide to Fermentation in Bioreactors | 4

Essential Guide to Fermentation in Bioreactors | 5

/// Why IKA HABITAT Bioreactors
are Optimal for Fermentation

Precise environmental control for fermentation
Mass flow controllers precisely regulate the input of air, nitrogen, and oxygen,
optimizing microbial growth during fermentation. Dissolved oxygen (DO) levels area critical parameter in this process.
A dedicated carbon dioxide supply system maintains optimal pH levels, whileheadspace gassing options facilitate efficient oxygen transfer with minimal
disturbance to the fermentation process. This precise control over thefermentation environment promotes consistent and reproducible results.

Advanced monitoring with next generation sensors
Advanced sensors for comprehensive bioprocess monitoring, including newgeneration sensors for biomass, cell viability, and off-gas analysis, offer highselectivity, sensitivity, and long-term stability. These sensors enable contaminationfree bioprocessing and improved operator efficiency by monitoring dissolved
carbon dioxide, conductivity, turbidity, Redox, cell viability, off-gas, temperatures,and non-intrusive foam.
Soft-sensors can be used to calculate and display specific batch data, such asparameter setpoints, organism-specific rates (μ, qs, RQ, etc.), and extended batchvalues (culture broth weight, biomass).

Reducing shear stress
IKA HABITAT Bioreactors have a reactor geometry with a pitched blade andimpeller design that ensures a gentle yet efficient mixing without the risk ofdamage from excessive shear forces. This approach optimizes the growth andmaintenance of suspension and sensitive adherent cells. A new chaotic mixing
mode that follows mathematical principles of chaotic-dynamic systems also
provides for a more homogeneous mixture.

Essential Guide to Fermentation in Bioreactors | 62023/// How IKA HABITAT Bioreactors Enhance Lab Operations
IKA HABITAT Bioreactors are more than mere cultivation tools; they are integrated solutions designed to enhance operations withsmoother, more efficient workflows tailored to the dynamic needs of our customers.

Award-Winning Design

Solutions that Scale

Recognized with the iF DESIGN AWARD 2023, the IKA
HABITAT Bioreactor integrates the capabilities of a bioreactor,
photobioreactor, and fermenter, reducing the need for multiple
setups and switching. Its ergonomic handling, intuitive
operation, and user-friendly features, such as an open skid,
unique lid stand, and lightweight components, reduce operator
fatigue and improve portability. The compact design maximizes
bench space. The bioreactor's intelligent support systems andcontrols make it accessible to both beginners and experts.

IKA HABITAT Bioreactors excel from micro-scale research toindustrial production. They feature a chaotic mixing option forfaster mixing, an advantage especially beneficial at the beginningof an experiment. The bioreactor’s design includes a range ofvessel volumes from 0.5L to 10L, available in both single anddouble-wall configurations. Properly-sized motors for eachvolume—small for up to 2L, and larger for 5L to 10L—ensure
efficient operation and customization in contrast to the standard
one-size-fits-all motor approach. Advanced, integrated control
systems guarantee consistent scale-up processes, enabling
seamless capacity growth.

Consistent Quality
The IKA HABITAT Bioreactor sets the benchmark for consistentquality in bioprocessing by ensuring that each production
cycle meets the high standards expected in the industry.
Its sophisticated control systems and precision engineering
provide a dependable foundation for operations, guaranteeing
uniform outputs that streamline the entire downstream process.
Variable-speed, bi-directional peristaltic pumps and an optional
fifth pump provide for diverse fluid management. This fidelity
in performance facilitates the scalability of production andsignificantly reduces the occurrence of batch failures, mitigating
downtime and waste.

Cross-Platform Integration
OPC UA integration and extensive interface options includingUSB, Ethernet, and RS-232 to provide comprehensive data
connectivity. The lid's additional ports enable customized
modifications to accommodate a range of bioprocessing
applications.

Global Presence, Local Support
IKA's global presence provides comprehensive support,
including technical service, spare parts, calibration, qualification,and commissioning, empowering customers to achieve theirbioprocessing goals.
Essential Guide to Fermentation in Bioreactors | 7

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MalaysiaBrazilVietnamGlobal Partner for BioProcessing Solutions
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Phone: +91 80 26253 900
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Phone: +1 910 452-7059
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