Scale up fermentation process (H.M.Moavia Atique)
- 1. SCALE UP FERMENTATION PROCESS H.M.MOAVIA ATIQUE (UNIVERSITY OF VETERINARY AND ANIMAL SCIENCES, LAHORE)
- 2. SCALE UP STUDIES Scale up studies are studies carried out at the laboratory or even pilot plant scale fermenters to yield data that could be used to extrapolate and build the large scale industrial fermenters. We try to build industrial size fermenters capable or close of producing the fermentation products as efficient as produced in small scale fermenters.
- 4. RULES FOLLOWED WHILE DOING SCALE-UP There are a few rules that are followed when doing scale up studies such as: 1) Similarity in the geometry and configuration of fermenters used in scaling up. 2) A minimum of three or four stages of increment in the scaling up of the volume of fermentation studies. 3)Each jump in scale should be by a magnitude or power increase and not an increase of a few litre capacity. Slight increase in the working volume would not yield significant data for scale up operation.
- 5. PURPOSE To ensure that the fermentation process is technically and economically viable to be produced in the end at a large scale. Allows investigation of a product and process on small and intermediate scale before large amount of money is invested on large scale production. To get the same fermentation efficiency as obtained in small scale fermenters at the most economical values. Failing of process at industrial scale causes Million Dollars loss so, scaling up gives investors more confidence on chances of success and against economic disaster.
- 6. Studies carried out during scale up includes Inoculum development Sterilization establishing the correct sterilization cycle at larger loads Environment parameters including nutrient availability, pH, Temperature, dissolved oxygen and dissolved carbon dioxide. Shear conditions, foam production.
- 7. STEPS IN SCALE-UP Define product economics based on projected market size and competitive selling and provide guidance for allowable manufacturing costs. Conduct laboratory studies and scale up planning at the same time. Conduct preliminary larger than laboratory studies with equipment to be used to aid in plant design. Design and construct a pilot plant including provisions for process and environment controls, cleaning and sanitization systems, packaging and waste handling system and meeting regulatory agency requirements. Evaluate pilot plant results(product and process) including product economics to make any corrections and a decision on whether or not to proceed with a full scale plant development.
- 8. A PILOT PLANT CAN BE USED FOR Evaluating the results of laboratory studies and making product and process corrections and improvements Producing small quantities of product for sensory, chemical, microbiological evaluations, limited market testing or furnishing samples to potential customers, shelf-live and storage stability studies Determining possible profitable by-products or waste stream requiring treatment before discharge Providing data that can be used in making a decision on whether or not to proceed to a full-scale production process; and in the case of a positive decision, designing and constructing a full-size plant or modifying an existing plant
- 9. Pilot plants are used to reduce the risk associated with construction of large process plants. Computer simulations and semi empirical methods are used to determine the limitations of the pilot scale. These mathematical models are then tested in physical pilot plant. Various modeling methods are used including Chemical similitude studies Mathematical modeling Finite elemental analysis Computational fluid dynamics
- 10. Chemical similitude studies Computer aided modelling and simulations in the development, integration optimization of the industrial process. Advanced Simulation Library Mathematical modeling Mathematical modeling is the process of using various mathematical structures - graphs, equations, diagrams, scatterplots, tree diagrams, and so forth - to represent real world situations.
- 11. Computational fluid dynamics Computational fluid dynamics (CFD) is the use of applied mathematics, physics and computational software to solve and analyze problems that involve fluid flows. Sim scale, SciLab. Finite elemental analysis Finite element analysis (FEA) is a computerized method for predicting how a product reacts to real-world forces, vibration, heat, fluid flow, and other physical effects. Finite element analysis shows whether a product will break, wear out, or work the way it was designed. Autodesk.
- 12. These gives information about Finalized mass and energy balance Optimized system design and capacity Equipment requirements System limitations After data has been collected from operation of a pilot plant, a larger production-scale facility may be built.