Equipment Application in Large-Scale Probiotic Production
Jan.15.2026
Core Equipment Configuration
The core equipment for this project is designed around the entire probiotic fermentation process, covering five key modules: Fermentation, Feeding, Media Preparation, Cleaning, and Mixing. The specific configuration is as follows:
(1) Core Fermentation System (4 sets)
A gradient volume fermenter combination is adopted to meet the requirements of the entire process from seed expansion to large-scale fermentation, ensuring precise capacity matching and maximum efficiency:
200L Fermenter: Used for seed activation and primary expansion, providing highly active and pure seed culture for subsequent fermentation. The tank is equipped with precise temperature control, pH monitoring, and a stirring system to ensure a stable seed culture environment.
1000L Fermenter: Undertakes the secondary expansion of the 200L seed culture to further increase biomass and activity, laying the foundation for large-scale fermentation. It is equipped with a high-efficiency aeration system and dissolved oxygen (DO) monitoring module to meet the oxygen demand of aerobic probiotic fermentation.
6000L Fermenter: The core production tank for large-scale probiotic cultivation. Constructed from hygienic grade stainless steel, it features a fully automatic control system for real-time monitoring and precise adjustment of key parameters (temperature, pH, DO, agitation speed). The single-batch fermentation cycle is stably controlled within 48-72 hours, ensuring high consistency between batches.
(2) Feeding System (1 set: 400L + 400L dual-tank combination)
To address the need for phased supplementation of nutrients (carbon sources, nitrogen sources, trace elements) during fermentation, two 400L feeding tanks are configured for the preparation, storage, and precise delivery of feeding solutions:
Independent Design: The dual-tank setup allows for the simultaneous preparation of two different feeding solutions (e.g., carbon and nitrogen sources), avoiding cross-contamination and improving feeding efficiency.
Precision Control: Equipped with precision metering pumps and online flow meters, the feeding rate can be adjusted in real-time based on the strain's growth status. This ensures the nutrient supply matches the metabolic demand, thereby increasing fermentation efficiency and strain yield.
(3) Media Preparation System (1 set: 1000L + 1000L dual-tank combination)
Responsible for the formulation, sterilization, and storage of fermentation media. The parallel design enables a "one tank in preparation + one tank on standby" continuous production mode to prevent downtime:
Integrated Functions: The tanks integrate heating, stirring, and sterilization functions, enabling rapid dissolution, uniform mixing, and high-temperature sterilization (121℃, 30min) to ensure media sterility.
Aseptic Transfer: After sterilization, the media can be directly transferred to fermenters or storage tanks via aseptic pipelines, reducing contamination risks during transportation and enhancing production continuity.
(4) CIP (Clean-in-Place) System (1 set: 4 × 1000L tank combination)
To ensure GMP compliance, four 1000L CIP tanks are configured for fully automatic in-situ cleaning of fermenters, feeding tanks, media tanks, and associated pipelines without manual disassembly:
Automated Process: The four tanks store alkaline cleaning solution, acidic cleaning solution, purified water, and disinfectant. A programmed sequence automatically executes "alkaline wash - water rinse - acid wash - water rinse - disinfection - final rinse," ensuring high efficiency and verifiable cleaning results.
Data Traceability: The entire cleaning process is monitored, with key parameters (time, temperature, concentration) recorded to meet GMP requirements for cleaning validation and data traceability.
(5) Mixing Module System (1 set: multi-volume combination)
Designed for post-fermentation mixing of bacterial broth with excipients and pre-treatment before powder formulation (e.g., adding protectants). The system includes 8 mixing tanks of varying capacities: 2×200L, 2×300L, and 4×600L.
Flexibility: The multi-volume design adapts to different batch sizes and product specifications, achieving a mixing uniformity error of ≤3%.
Gentle Mixing: Special agitator blades are installed to ensure uniform mixing of the broth with protectants or carriers while minimizing shear stress to protect probiotic viability. The hygienic design ensures no dead corners and easy cleaning.
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