Industrial fermentation tank

Types of Industrial Fermentation Tanks

An industrial fermentation tank is a large vessel used to facilitate the process of fermentation in various industrial applications, such as food and beverage, pharmaceuticals, and chemicals. There are several types and designs of large-scale fermentation vessels, including rectangular fermenters, beer fermenters, and stainless steel fermenters.

• Rectangular fermenter: The bioreactor fermenter is typically made up of an upper compartment (fermentation tank) and a lower drain or storage compartment (claimer) placed at an angle that allows the final product to exit. This vessel is commonly used in the production of herbal products, lactic acid, organic matter, and amino acids, among others. It comprises an inner tank, outer tank, and roof exhaust.
• Beer fermenter: Beer fermenters are cylindrical tanks constructed from stainless steel or fiberglass, located in breweries. They provide the ideal settings for yeast to thrive and complete its job of turning sugar into alcohol and carbon dioxide, producing beer in the process. Hence, they are also referred to as brewery fermenters.
• Stainless steel fermenter: The stainless steel fermenter is the main piece of equipment for fermentation and storage. It is fully controlled under the microscope and with no complications. After the fermentation process is finished, the flax tanks are usually taken care of in the bottling or kegging unit.

Specification and Maintenance of Industrial Fermentation Tanks

The industrial fermentation tank usually comes with some specifications that can be adapted to different industrial needs.

• Volume Size

  The volume size of a fermentation tank can vary widely depending on its intended use and the industry in which it is employed. From small laboratory-scale fermenters with volumes measured in liters to large-scale industrial fermenters that hold thousands of liters, there's a fermentation tank with the right size for every need.

• Material

  Industrial fermentation tanks are most often constructed from stainless steel. Its corrosion-resistant and easily-sanitized qualities make it an optimal choice to ensure the product's purity and safety. Other materials such as glass, plastic, and alloy carbon are also available for specific needs.

• Temperature and pH Control

  These tanks can control temperature and pressure to create the ideal environment for the growth of the organisms being used to carry out the fermentation process. They also have pressure resistance. A fermentation tank's ability to withstand certain levels of pressure is essential, particularly in industries where high-pressure processes are the norm. Fermentation tanks can be built to withstand higher pressures, with fermentation under higher pressure improving product yields and process efficiency.

• Cleaning and Maintenance Systems

  These industrial fermentation tanks often feature far more advanced cleaning and maintenance systems than smaller tanks. The cleaning system is often automatic, making the cleaning process more efficient and hygienic, reducing the need for manual work.

Maintenance

The maintenance of an industrial fermentation tank is often crucial to the efficiency of the fermentation process and the quality of the final product. As mentioned above, many fermentation tanks now come with advanced automatic cleaning systems, so the maintenance is simplified, but it is still essential to ensure that the automatic system is functioning effectively, and regular checks of the fermentation tank may still be necessary.

• Periodic Cleaning: Even if the automatic cleaning system is in place, it's essential to clean the tank thoroughly from time to time, removing any residue and deposits that may remain after the cleaning process to prevent cross-contamination.
• Maintenance of the sterilization system: This is crucial. Regular checks and maintenance of the sterilization system, including its consumables, are imperative to ensuring the tanks' hygiene and safety.
• Parts Inspection: The key components of an industrial fermentation tank must be inspected periodically. These include valves, pipes, temperature, and pressure sensors, sealing elements, and stirring devices, among others.
• Applicable lubricants should be carefully used and applied to the movable parts, such as the stirring device, to ensure smooth operations.

Scenarios of industrial fermentation tanks

The industrial fermenter plays a crucial role in several industries ranging from food to pharmaceuticals. Below are some uses in various industries.

• Food Processing Industry: The food industry uses fermentation tanks for controlled fermentation processes. Such a process leads to the production of a range of products such as yogurt, cheese, sauerkraut, sourdough bread, and fermented beverages like kombucha and kefir. The tanks provide an ideal environment for the growth of specific microorganisms that bring about desired flavors, textures, and preservation qualities in fermented food.
• Alcohol Production and Brewing: Fermentation tanks are a must in brewing industries and wineries. For brewing industries, they are used to produce alcoholic beverages such as beer, whiskey, vodka, and wine. The tanks provide a conducive environment for yeast to convert sugars present in grains or fruits into alcohol and carbon dioxide, thereby determining the beverage's taste and aroma.
• Pharmaceutical Industry: In the pharmaceutical field, fermentation tanks allow for the precise and reproducible production of antibiotics, amino acids, vitamins, hormones, and other pharmaceutical compounds. Engineering design, along with strict monitoring and control systems, helps to produce safe and effective products for the industry.
• Biotechnology and Genetic Engineering: Biotech companies rely heavily upon fermentation tanks for expressing genetically engineered organisms that manufacture insulin, monoclonal antibodies, vaccines, and other complex proteins. The customized tanks facilitate large-scale cultivation of genetically modified microorganisms or cell lines that serve as factories for producing these valuable biomolecules used in medical treatments and therapies.
• Animal Feed Production: Animal feed production employs fermentation tanks to prepare silage, a fermented feed made from green vegetation or high-moisture grains. The fermenters support the growth of beneficial bacteria that preserve the feed, making it nutritious and safe for livestock consumption. Silage improves the animal's digestion.
• Bioremediation and Environmental Applications: Fermentation tanks can help in the development of biofertilizers and bioremediation agents. They are ideal for cultivating beneficial microorganisms in the soil that support plant growth. The tank can also foster the growth of microbes that breakdown pollutants and toxins, thereby supporting environmental clean-up processes.
• Research and Development: Fermentation tanks are used for research purposes by academic institutions, agricultural biotechnology companies, and food technology organizations. The small and lab-scale fermenters are employed for R&D to understand fermentation processes better, discover new strains with beneficial traits, and optimize fermentation techniques for improving product quality and yields.
• Chemical Industry: Chemical industries use fermentation tanks to produce chemicals and organic compounds through biological processes. Some of the chemicals produced include solvents, organic acids, alcohols, and biofuels. The tanks promote the activity of specific microorganisms responsible for converting renewable feedstocks into valuable chemical products, thereby promoting sustainability and reducing dependence on fossil fuels.

How to Choose Industrial Fermentation Tanks

The following factors should be considered when choosing industrial fermentation tanks:

• Capacity

  The tank capacity should be large enough to ensure the required volume for the fermentation process. It needs to consider factors like batch size, the number of tanks, and the growth requirements of microorganisms.

• Material

  Fermentation tanks are usually made of stainless steel, which is fabrication-friendly and can withstand harsh fermentation environments. Additionally, the material needs to be easily cleaned and sterilized to prevent contamination.

• Design

  A good industrial fermentation tank design can optimize the fermentation process. The options include cylindrical tanks and conical tanks for specific applications. The tanks should also be equipped with an aeration system that allows for gas exchange between the microorganisms and the environment.

• Temperature Control

  Microbial fermentation may need to operate within a specific temperature range. Therefore, temperature control is crucial for the consistent and repeatable success of fermentation processes. Buyers should choose tanks with integrated heating/cooling jackets or external heat exchangers.

• Automation and Monitoring

  Automation and monitoring systems are crucial for the precise and repeatable control of fermentation processes. Thus, buyers should consider the availability of specific sensors, controllers, and data logging capabilities.

• Cleanability

  Cleaning and sanitization are critical to avoid cross-contamination with other products. Buyers should choose tanks that allow for effective cleaning and sanitization.

Industrial fermentation tank FAQ

Q1: What is an industrial fermentation tank used for?

A1: An industrial fermentation tank is a vessel used to grow organisms for various commercial purposes, such as antibiotic production, organic compound synthesis, enzyme production, and fermentation of carbohydrates into alcohol.

Q2: What are some characteristics of fermentation tanks?

A2: The tanks are normally made of stainless steel to prevent rust and allow easy cleaning. They also have temperature and pressure control systems that allow operators to create optimal environments for the organisms being cultivated. Some tanks also have stirrers or agitators to mix the content and ensure even distribution of nutrients.

Q3: Can buyers get customized fermentation tanks?

A3: Yes. Buyers can get customized fermentation tanks tailored to their specific requirements. They can request for tanks with additional features such as special pH control systems or a particular membrane filtration setup.