Continuous Fermentation & Fed-Batch Fermentation
Industrial biotechnology customers today face major challenges including low production efficiency together with unstable product quality and elevated operational costs. We recognize the substantial impact these challenges can have on your business expansion. We provide Continuous Fermentation and Fed-Batch Fermentation technical services using our expert technical team, cutting-edge equipment and extensive industry experience to help you reach efficient, stable production that saves you money.
Challenges We Help Solve
1. Boosting Production Efficiency
Our Continuous Fermentation technology enables microorganisms to stay in their exponential growth phase which results in a considerable rise in production output over time. This production method excels in large-scale continuous manufacturing operations that produce biofuels, organic acids and bulk chemicals.
Our Fed-Batch Fermentation service is designed for high-value products demanding multiple small-scale batches like pharmaceuticals and biologics. The product yield rises and the microbial growth phase extends when fresh substrates are added periodically.
2. Ensuring Product Quality Consistency
Our system employs advanced online monitoring and automated control systems which maintain continuous observation of crucial fermentation parameters including temperature and dissolved oxygen while adjusting these conditions automatically in real time. Our methods deliver stable product quality which traditional fermentation methods find difficult to maintain.
3. Reducing Production Costs
Our process optimization of fermentation and feed strategies enables maximum nutrient use efficiency and waste reduction which results in substantial cost savings. Our single-use bioreactor platform offers easy operation and cost-effectiveness while eliminating cross-contamination risks which decreases production process hazards.
The fed-batch fermentation process. (Wang X L., et al., 2020)
Schematic diagram of continuous fermentation. (Guo Y., et al., 2022)
Simplified scheme of (a) batch, (b) fed-batch, and (c) continuous fermentation. (Paulová L., et al., 2013)
Services We Offer
Strain Development and Optimization
Strain Screening and Engineering: Customized construction of high-yield strains based on client requirements; optimization of gene expression systems to ensure high activity and stability during fermentation.
Engineered Strain Optimization: Development of industrial-grade strains through techniques such as gene optimization, expression plasmid construction, and positive strain selection.
Fermentation Process Optimization
Medium Optimization: Design of high-efficiency culture media formulations with optimized nutrient composition to improve fermentation efficiency.
Feeding Strategy Development: Precise feeding strategies to ensure efficient nutrient utilization during fermentation and minimize accumulation of by-products.
Environmental Control: Accurate control of fermentation conditions (e.g., temperature, pH, dissolved oxygen) to ensure process stability and consistency.
Large-Scale Production
GMP-Grade Manufacturing: Production services that comply with GMP standards to ensure product quality meets international regulations.
Automated Control: Implementation of modern automation systems for real-time monitoring of the fermentation process to guarantee production efficiency and consistent product quality.
Purification and Formulation Development
Purification Process Optimization: Achieving high-purity target products through techniques such as hydrophobic interaction chromatography, affinity chromatography, and gel filtration.
Formulation Optimization: Development of stable formulations to extend product shelf life.
Service Workflow
- Project Consultation: Understand client needs and provide professional advice and tailored solutions.
- Solution Design: Develop detailed fermentation process plans, including strain selection, media formulation, and fermentation condition control.
- Lab-Scale Trials: Conduct experiments on small-scale fermenters to validate process feasibility and optimize parameters.
- Pilot-Scale Trials: Scale up production and further refine the process to ensure stability and reproducibility.
- Large-Scale Manufacturing: Perform GMP-compliant large-scale production with strict process control to ensure product quality.
- Delivery and Support: Deliver products on time and provide technical support and after-sales service.
Service Advantages
Efficient Production: Continuous Fermentation keeps microorganisms in the exponential growth phase, increasing productivity per unit time. Fed-Batch Fermentation extends the growth cycle by intermittently feeding fresh substrates, boosting product yield.
Cost Savings: Optimized fermentation processes and feeding strategies enhance nutrient utilization, reduce waste, and lower production costs.
Stable Quality: Precise control of fermentation conditions and process parameters ensures consistency and stability in product quality.
Applications by Industry
Food Industry
Traditional Fermented Foods: Techniques such as continuous and fed-batch fermentation are widely used to improve yield and quality in the production of soy sauce, vinegar, alcoholic beverages, etc.
Functional Foods: For example, plant-based fermented foods like soy yogurt benefit from optimized fermentation conditions, resulting in longer shelf life and improved taste.
Food Additives: Fermentation is used to produce amino acids (e.g., L-glutamic acid, L-leucine), organic acids (e.g., lactic acid, citric acid), and other food additives.
Recombinant Protein Production: Fed-batch fermentation is widely used for producing recombinant proteins (e.g., insulin, antibodies, vaccines) through high cell density fermentation (HCDF) to increase yield and activity.
Antibiotics and Enzyme-Based Drugs: Fed-batch fermentation plays a vital role in the production of antibiotics (e.g., penicillin, cephalosporins) and industrial enzymes (e.g., amylase, protease).
Potential of Continuous Fermentation: The application of continuous fermentation in biopharmaceuticals is under active research, especially for improving production efficiency and reducing costs.
Organic Fertilizers and Animal Feed: Fermentation techniques convert crop waste into organic fertilizers or animal feed, such as using mushroom substrates to produce organic fertilizers.
Biopesticides and Biofertilizers: Fermentation is used to produce microbial pesticides and biofertilizers for pest control and soil improvement in agriculture.
Environmental Engineering
Wastewater Treatment: Continuous fermentation technology enhances microbial metabolism in wastewater treatment, improving processing efficiency.
Bioenergy Production: Fermentation is used to produce biofuels (e.g., ethanol, methane), reducing reliance on conventional energy sources.
Chemical Production
Bio-Based Chemicals: Fermentation enables the production of bio-based chemicals (e.g., bioplastics, bio-rubber) as alternatives to traditional petrochemical products.
Fine Chemicals: Fed-batch fermentation excels in producing fine chemicals such as vitamins, flavors, and pigments.
Other Fields
Cosmetics and Skincare: Fermentation technology shows potential in producing skincare ingredients like hyaluronic acid and collagen.
Biosensors and Biomaterials: Fermentation is used to produce the enzymes and proteins required for biosensors and biomaterials.
FAQs
1. How can stable microbial growth be maintained during continuous fermentation and fed-batch fermentation?
In continuous fermentation, microorganisms can remain in the exponential growth phase for an extended period by maintaining a stable supply of nutrients and environmental conditions. In fed-batch fermentation, nutrients are gradually added to extend the exponential growth phase, preventing overconsumption of nutrients.
2. What issues should be considered in the operation and maintenance of fermentation equipment?
Fermentation equipment should be regularly cleaned and maintained to ensure proper operation. For continuous fermentation, particular attention should be paid to maintaining an aseptic environment and a stable supply of nutrients.
