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ESSENTIAL GUIDE TO BIOREACTORSThe Role of Bioreactors in Modern Bioprocessing
Bioreactors are advanced equipment that are

IKA HABITAT Bioreactors offer outstanding

essential in modern biotechnology. They provide

features and benefits over traditional

optimal environments for the growth of cells

bioreactors in biological processes thator microorganisms. Equipped with sensors

optimize the quality of the final product andand software, they control growth conditions,enable its scalability. In certain applications,maintain optimal parameters, and improve

this technology is indispensable, enablingefficiency, quality, and yields. They also enable

contemporary biotechnological advancements

the transfer of optimized conditions from thebeyond the reach of traditional methods.

/// Critical Applications for Bioreactors inModern Bioprocessing
Bioreactor applications work with two main types of organisms: mammalian/animal cells or
microorganisms, such as bacteria, yeast, and fungi. Depending on the organism, the process is called
fermentation for microbial cultures or cell culture for mammalian and animal cells.

lab to industrial scale, allowing for the mass
production of cells or cell-derived products.

Cell Applications
Mammalian & Insect Cells

Microorganism Applications
Bacteria, Fungi, Algae Cells

Protein Production› Cultured meat
› Protein-based drugs› Products for diagnostic testing› Monoclonal antibodies› Enzymes

Protein Production› Enzymes such as cleaning
agents, paper production› Food supplements› Hormones (insulin), humanserum albumin (HSA)

Cell Production› Extended preservation inbiobanks› Mass cell production for diagnostic tests› Gene therapy› Regenerative medicine orresearch

Chemical Production› Biofuels (ethanol, hydrogen,methane)› Biopolymer and sustainablechemicals› Novel synthesis routes foravailable chemicals

Virus Production› Virus-based drugs(e.g. vaccines)

Essential Guide to Bioreactors | 2

Microorganism Production› Microbial bioremediation
agents› Brewing/baking supplies(yeast, microorganisms)› Brewing products(wine, beer, spirits)

Essential Guide to Bioreactors | 3

Scaling processes from the laboratory to industrial production presents numerous challenges.
Bioreactors enable the transition of organisms from small-scale experimental setups to large-scale
production units while maintaining their essential characteristics. This is achieved by exerting strict
control over culture parameters throughout the scaling process. Maintaining precision during scale-up
is crucial for consistent product quality, as it minimizes variations in the growth environment that could
alter the organisms' behavior or the target product's composition. This level of precision is crucial forthe consistent quality of the end product.

/// Importance of Bioreactors for Cell
Culture and Fermentation
Bioreactors facilitate cell culture and fermentation processes, enabling various biologicalreactions. They allow researchers and manufacturers to employ different cultivation
methods, including batch, fed-batch, and continuous culture.

Cells

Mammalian (Human, Animal) & Insect cells

Microorganisms

Bacteria, Fungi (mainly yeast),Algae (Plant) cells

Further expansion into flasks

Cell factory systems or roller bottles

Grow in suspension
or adherent (require a surface
to attach, e.g. microcarriers)

microcarrier

Always grow in suspension
Petri dish or
frozen stock culture

Expansion into flask

Scaling biological processes from the lab

Bioreactors are designed to provide a controlled andprecisely regulated environments that emulate thenatural living conditions necessary for cell growthand product formation. They are equipped witha variety of sensors that accurately measure andadjust key parameters such as pH, temperature,oxygen levels, and nutrient availability. By precisely
controlling these environmental factors, bioreactors
create an environment that meets the specificphysiological and metabolic requirements of the cells
or microorganisms being cultured. This customized
environment promotes optimal growth conditions
and enhances the production of desired biologicalproducts.

Essential Guide to Bioreactors | 4to industrial production: traditional andbioreactor-based strategy

Bioreactor based cell expansion

The data-driven nature of modern bioreactors
provides a wealth of information that canbe used to optimize growth parameters andprocess kinetics. Equipped with advanced
sensors and data recording systems, thesebioreactors can continuously monitor andrecord various environmental and biologicalvariables, such as pH, temperature, dissolved
oxygen, nutrient levels, and metabolite
concentrations. By analyzing the data
generated during the cultivation process,researchers and manufacturers can gainvaluable insights that lead to improvements
in scalability, efficiency, and yield. These datadriven optimizations enable the continual
advancement of cellular and microbial
production, making the bioreactor not justa vessel for growth, but a dynamic tool forprocess enhancement.

Essential Guide to Bioreactors | 5

/// Why IKA HABITAT Bioreactors
are Optimal to Support Cell
Culture and Fermentation?

Precise environmental control for cell cultivation
Mass flow controllers precisely regulate the input of air, nitrogen, and oxygen,
optimizing cell growth. Dissolved oxygen (DO) levels are a critical parameter in thisprocess.
A dedicated carbon dioxide supply system maintains optimal pH levels, whileheadspace gassing options facilitate efficient oxygen transfer with minimal cellular
perturbation. This precise control over the cell culture environment promotes
consistent and reproducible experimental 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 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 DesignSolutions 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.

Worldwide 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 Bioreactors | 7United Kingdom

Germany
PolandUSA

ThailandTurkey

China

Spain

UgandaJapanIndia

Kenya
Korea

MalaysiaBrazilVietnamGlobal Partner for BioProcessing Solutions
GERMANY
IKA-Werke GmbH & Co. KG
StaufenPhone: +49 7633 831-0
sales@ika.de

MALAYSIA
IKA Works (Asia) Sdn Bhd
Kuala Lumpur (Rawang)
Phone: +60 3 6099-5666
sales.lab@ika.my

INDIA
IKA India Private Limited
Bangalore
Phone: +91 80 26253 900
info@ika.in

USA
IKA Works, Inc.
Willmington
Phone: +1 910 452-7059
sales@ika.net

CHINA
IKA Works Guangzhou
Guangzhou
Phone: +86 20 8222 6771
info@ika.cn

BRASILIKA Brasil
Campinas/Rio de Janero
Phone: +55 19 3772-9600
sales@ika.net.br

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