Scale up of fermentation
- 2. Fermentation Definition Importance of scale up studies Steps in scale up Scale of fermentation process(Large scale, Small scale& Pilot scale) Optimizing scale up of fermentation process Rules followed while doing scale up Studies carried out during scale up References CONTENTS
- 3. FERMENTATION: Fermentation is a metabolic process that produces chemical changes in organic substrates through the action of enzymes. EXAMPLES: Yeast perform fermentation to obtain energy by converting sugar into alcohol. HISTORY OF FERMENTATION: Louis pasteur became the first scientist to study fermentation. He showed that lactic acid fermentation is caused by living organisms.
- 4. DEFINITION: Scale up of a fermentation process is to demonstrate fermentation production at large scale resulting in the same productivity and quality as that developed at small scale.
- 5. IMPORTANCE OF SCALE UP STUDIES: More important during scale up exercises is that we trying to build industrial size fermentor capable (or) close of producing the fermentation products as efficient as those produced in small scale fermentors. It must be appreciated as the size of fermentation increases during scale up various parameters measured might not show a predictable linear co-relationships. Certain parameters changes. Some remained constant. Some parameters need to be modified & adjusted during scale up studies.
- 6. STEPS IN SCALE UP: Define product economics based on projected market size & competitive selling & provide guidance for allowable manufacturing costs. Conduct laboratory studies and scale-up planning at the same time. Define key rate- controlling steps in the proposed process. Conduct preliminary larger-than-laboratory studies with equipment to be used in rate- controlling step to aid in plant design.
- 7. STEPS: Design and construct a pilot plant including provisions for process and environmental controls, cleaning and sanitizing systems, packaging and waste handling systems, and meeting regulatory agency requirements. Evaluate pilot plant results (product & process) including process economics to make any corrections and a decision on whether or not to proceed with a full scale plant development.
- 8. SCALE UP OF FERMENTATON PROCESS:
- 9. LARGE -SCALE FERMENTATION: Large- scale fermentations are utilized to create massive quantities of ethanol which are used for food production, alcohol production, and even gasoline production. Yeast is the microorganisms which is used for a large scale production of alcohol.
- 10. SMALL SCALE FERMENTATION: Small scale fermeter are same as large fermenter(bioreactor). They are 2 types: Bench scale & lab scale system. They are small but highly automated and customized for the application. They can be lab as CSTR / autoclave fixed, fixed on fluidized bed reactor application.
- 11. PILOT SCALE FERMENTATION: A pilot scale fermenter is a small industrial system, which is operated to generate information about the behavior of the system for use in design of larger facilities. Pilot plant is a relative term in the sense that plants are typically smaller than full scale production plants, but are built in a range of sizes.
- 12. Various modeling methods are used including Chemical similitude studies Mathematical modeling Finite elemental analysis Computational fluid dynamics 1) Chemical similitude studies: Computer aided modeling and simulations in the development, intergration optimization of the industrial process.
- 13. 2) Mathematical modeling: Mathematical modeling is the process of using various mathematical structures – graphs, equations, diagrams, scatter plots and so forth- to represent real world situations. 3) Finite elemental analysis: FEA is a computerized method for predicting how a product reacts to real – world forces, vibration, heat, fluid flow and other physical effect. It shows whether a product will break, wear out, (or) work the way it was designed.
- 14. 4) Computational fluid dynamics: CFD is the use of applied mathematics, physics and computational software to solve & analyze problems that involves fluid flows.
- 17. RULES FOLLOWED WHILE DOING SCALE-UP: There are a few rules of the thumb followed when doing scale up studies such as: 1 ) Similarity in the geometry and configuration of fermentors 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 power increase & not an increase of a few litre capacity. Slight increase in the working volume would not yield significant data for scale up operation.
- 18. STUDIES CARRIED OUT DURING SCALE UP: Inoculum development Sterilization establishing the correct sterilization cycle at larger loads Environmental parameters such as nutrient availability, pH, temperature, dissolved oxygen, dissolved carbon dioxide. Shear conditions, foam production
- 19. REFERENCES: S. N0 BOOK NAME AUTHOR’S NAME PUBLICATI ON NAME YEAR 1. BOOK OF BIOTECHNOLOGY SATYANARAYAN A U. 2010 2. PRINCIPLES OF FERMENTATION TECHNOLOGY PETER F. STANBURY, ALLAN WHITAKER, STEPHEN J.HALL FIRST EDITION 1984 3. MANUAL OF INDUSTRIAL MICROBILOGY AND BIOTECHNOLOGY ARNOLD L. DEMAIN, JULIAN E. DAVIES, RONALD M. ATLAS MORE EDITION 1999