How to choose a suitable bioreactor? A comprehensive guide from laboratory to industrialization!
Choosing a bioreactor requires consideration of "demand performance cost", which should not only meet current process requirements but also reserve space for technological upgrades.
一、 Clarify core requirements: Starting from application scenarios
1 Select based on the characteristics of the biological system and cell type: mammalian cells are sensitive to shear forces and need to choose air lift or wave reactors to reduce mechanical damage; Filamentous microorganisms (such as fungi) require a fixed bed reactor with low stirring intensity.
According to the type of reaction: anaerobic fermentation requires sealed tanks and gas recovery systems; Aerobic cultivation (such as antibody production) requires efficient dissolved oxygen transfer design, such as mixing tanks with microporous aerators.
2. According to the scale and production capacity, if it is in the laboratory stage, 2-50L glass or small disposable reactors are suitable for process development and support flexible parameter adjustment.
If it is industrial production, stainless steel reactors (made of 304/316L material) are suitable for stable mass production (such as vaccine production).
3. According to the cultivation method, if it is suspension cultivation, stirred tanks or wave reactors can be selected for suspension cells (such as hybridomas), which have high mixing efficiency and are easy to scale up.
If it is adherent culture, a fixed bed reactor can be selected to provide high surface area through a mesh carrier, supporting high-density adherent cell growth.
4、 Select based on key technical parameters Consider selecting appropriate stirring blades for shear force control, and prioritize inclined blades or magnetic stirring for animal cell culture to avoid high shear damage from turbine blades; Microbial fermentation can use turbine blades to enhance dissolved oxygen transfer.
Consider fluid dynamics optimization by eliminating vortices through baffles or using a dual axis swing reactor (such as XRS 20) to improve mixing uniformity and reduce cell aggregation.
5. Considering the efficiency of mass and heat transfer, precise dissolved oxygen (DO) control should be considered. Escherichia coli fermentation requires maintaining a dissolved oxygen saturation of 30% -50%, which can be improved by membrane aeration or oxygen enriched ventilation; Enzyme catalyzed reactions need to avoid excessive aeration that can cause protein denaturation.
Considering precise temperature and pH regulation, the jacketed heat exchange system (with an accuracy of ± 0.5 ℃) is combined with automatic acid-base replenishment to meet the pH requirements of mammalian cells at 7.0-7.4.
6. Consider sensor integration for automation and monitoring systems: real-time feedback from pH, DO, and temperature probes, combined with SCADA system to achieve parameter closed-loop control; A disposable reactor can use wireless sensors to simplify the verification process.
二. Material and Compliance Stainless Steel: 316L stainless steel requires ASME BPE certification and is suitable for long-term continuous production;
The sealing element is made of PTFE material to prevent chemical corrosion.
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