Submerged Fermentation (SmF)
Our professional Submerged Fermentation (SmF) technology services exist to guide you through the essential obstacles faced during fermentation-based production processes. Submerged Fermentation (SmF) technology enables businesses to decrease production timeframes while minimizing expenses and improving both product quality and consistency. Through optimized fermentation conditions and streamlined process workflows we enable you to address traditional fermentation challenges including inefficient production rates and expensive purification processes.
Our end-to-end services guide your project from strain development through fermentation process optimization to achieve fast commercialization. Our SmF technology delivers efficient and reliable solutions that meet your specific requirements for producing enzymes or bioactive molecules and other high-value products.
Submerged Fermentation Services
Strain Development and Optimization
Strain Screening and Improvement: We offer screening and enhancement services for high-yield strains to meet customer specifications and enable efficient target product expression.
Genetically Engineered Strain Construction: Our process involves using gene cloning and expression vector design to develop engineered strains that function well in submerged fermentation.
Fermentation Process Development
Lab-Scale Fermentation Trials: Laboratory settings host small-scale fermentation processes to confirm strain development conditions and assess product expression efficiency.
Pilot-Scale Upscaling: The fermentation processes are enhanced by lab results and product yield and quality assessment prepares the production for large-scale execution.
Process Optimization: Optimal fermentation outcomes and enhanced product yield result from the adjustment of key parameters including media composition, pH, temperature, and dissolved oxygen levels.
Fermentation Production Services
Large-Scale Fermentation: Our services include fermentation capabilities from 250 mL shake flasks to 500 L bioreactors with full support throughout the stages from preclinical development to commercial production.
Continuous and Batch Fermentation: We select appropriate fermentation modes based on product needs which include both continuous and batch fermentation.
Quality Control and Analysis
Product Purification: The application of several purification methods like affinity chromatography and ion exchange helps to achieve high product purity and efficient recovery rates.
Quality Testing: To verify product purity and functionality and to ensure adherence to quality standards scientists utilize HPLC and SDS-PAGE testing methods.
Stability Testing: Our stability testing includes both accelerated and long-term assessments which help maintain product stability throughout storage and transportation processes.
GMP Manufacturing and Delivery
GMP-Grade Production: Every production process follows GMP standards to maintain international quality standards for each batch.
Customized Packaging and Logistics: We offer personalized packaging solutions that align with client requirements and utilize cold chain logistics to maintain product safety during delivery.
Submerged Fermentation Services Workflow
- Project Consultation & Requirement Analysis: Engage in in-depth communication with clients to understand their specific needs, target products, and expected outcomes. We offer professional advice and solutions to help clients define the direction and focus of the project.
- Project Evaluation & Quotation: Based on client requirements, we assess project feasibility, costs, and timelines. A detailed quotation is then provided to ensure clients have a clear understanding and expectations for the project.
- Strain Development & Optimization: According to the target product, we carry out strain screening, modification, and genetic engineering to ensure high-yield, stable, and robust strains—laying a solid foundation for subsequent fermentation process development.
- Fermentation Process Development & Optimization: At a lab scale, we develop and optimize fermentation processes, including medium formulation, fermentation condition adjustments (such as temperature, pH, and dissolved oxygen), and fermentation duration determination, to maximize product yield and quality.
- Pilot Scale-Up & Validation: We scale up the optimized fermentation process to pilot scale for verification and further optimization. Potential issues during scale-up are addressed to ensure process stability and reproducibility.
- Large-Scale Production: Large-scale fermentation is carried out in GMP-compliant production facilities, strictly following operational procedures and quality control standards to ensure each batch meets customer requirements and international standards.
- Quality Control & Analysis: Strict quality control and analytical testing are performed on raw materials, intermediates, and final products—including purity analysis, activity assays, and stability testing—to guarantee product quality and safety.
- Product Delivery & After-Sales Service: Qualified products are packaged and delivered according to customer specifications. Comprehensive after-sales services—including technical support, product consultation, and service assurance—are provided to ensure customer satisfaction.
Advantages of Submerged Fermentation Services
Professional Team: We have a team of experienced microbial fermentation experts and engineers with deep expertise and practical experience in strain development, fermentation process optimization, and production management. They are capable of providing high-quality solutions tailored to client needs.
Advanced Technology: Equipped with state-of-the-art fermentation equipment and analytical instruments—such as high-precision fermenters, online monitoring systems, and high-performance liquid chromatography (HPLC)—we ensure precise control of fermentation processes and consistent, reliable product quality.
Customized Services: We offer personalized fermentation process development and production services based on each client's specific needs and target products. From strain screening to final product purification and packaging, every step can be customized according to client requirements.
Strict Quality Control: We adhere to a rigorous quality management system encompassing raw material sourcing, process monitoring, and finished product inspection, ensuring that every batch meets international standards and client specifications.
Efficient Delivery: With robust production and delivery capabilities, we can respond quickly to customer demands, complete projects on schedule, and deliver high-quality products to accelerate time-to-market.
Cost-Effectiveness: By optimizing fermentation processes and production workflows, we reduce production costs and offer clients better value. We also provide flexible pricing options to accommodate diverse client needs.
Application of Submerged Fermentation
Antibiotic Production: Submerged fermentation is one of the primary methods for producing antibiotics such as penicillin and streptomycin. Optimized fermentation conditions help enhance yield and quality.
Enzyme Production: Many enzymes such as proteases, amylases, and cellulases are produced through submerged fermentation. These enzymes are used in drug synthesis, degradation, and modification processes.
Bioactive Molecule Production: Submerged fermentation is suitable for producing a variety of bioactive molecules such as polysaccharides, peptides, and nucleotides. These molecules have broad pharmaceutical applications as drug carriers, immune modulators, etc.
Food and Beverage Industry
Food Additive Production: Submerged fermentation is used to produce additives such as citric acid, lactic acid, and glutamic acid, which improve taste and extend shelf life in food products.
Flavor Enhancer Production: Products such as soy sauce and vinegar are produced via fermentation, where microbial enzymes break down raw materials to generate unique flavors.
Alcoholic Beverage Production: Submerged fermentation is a key step in making alcoholic beverages like beer and wine. Yeasts convert sugars into alcohol and carbon dioxide, contributing to flavor and alcohol content.
Biofuel Industry
Bioethanol Production: Using submerged fermentation technology, biomass such as corn and sugarcane can be converted into bioethanol. Bioethanol is a renewable and clean energy source that can serve as an alternative or additive to gasoline.
Biobutanol Production: Biobutanol is another important biofuel whose production also relies on submerged fermentation. Compared to bioethanol, biobutanol has a higher energy density and better fuel properties.
Biopesticide Production: Submerged fermentation can be used to produce biopesticides, such as Bacillus thuringiensis (Bt) toxins. These biopesticides are environmentally friendly and exhibit low toxicity to non-target organisms, making them an ideal alternative to traditional chemical pesticides.
Biofertilizer Production: Submerged fermentation enables the production of biofertilizers containing beneficial microorganisms, such as nitrogen-fixing bacteria and phosphate-solubilizing bacteria. These microbes promote plant growth and enhance soil fertility.
Environmental Industry
Wastewater Treatment: Submerged fermentation technology can be applied in wastewater treatment, where microbial metabolism decomposes organic matter in wastewater, reducing Chemical Oxygen Demand (COD) and Biological Oxygen Demand (BOD) to achieve purification.
Bioremediation: In the field of environmental restoration, submerged fermentation can be used to produce microorganisms and enzymes for bioremediation. These biological agents degrade pollutants in soil and water, helping to restore the ecological environment.
FAQs
1. What is Submerged Fermentation?
Submerged Fermentation is a microbial fermentation technique in which microorganisms grow while suspended in a liquid culture medium. This liquid medium contains dissolved or suspended nutrients and is used to produce industrial enzymes, antibiotics, bioactive molecules, and more.
2. What are the methods of Submerged Fermentation?
There are two main methods:
Batch Fermentation: Sterilized growth nutrients are added during the fermentation process. This method is suitable for increasing cell density and simplifying product recovery.
Continuous Fermentation: In an open system, sterilized liquid nutrients are added to the fermenter at a constant rate while the converted nutrient solution is simultaneously withdrawn, maintaining steady-state fermentation conditions.
3. What are the advantages of Submerged Fermentation?
Short production cycle: The fermentation conditions (e.g., temperature, pH, dissolved oxygen) can be precisely controlled to enable rapid production.
Low cost: Low-cost industrial and agricultural by-products can be used as substrates.
Simple product purification: Since the microorganisms secrete products into the fermentation broth, recovery can be done through filtration, centrifugation, or chromatography.
High yield: It is suitable for large-scale industrial production.
4. What are the limitations of Submerged Fermentation?
Complex equipment: Requires sophisticated fermentation equipment and control technology.
Large volume of wastewater: A significant amount of wastewater may be generated during fermentation, requiring additional treatment.
Lower product concentration: Compared to solid-state fermentation, product concentration may be lower.
5. What types of microorganisms are suitable for Submerged Fermentation?
Submerged Fermentation is suitable for a variety of microorganisms, including bacteria, yeast, and filamentous fungi.
6. Is Submerged Fermentation suitable for large-scale production?
Yes, Submerged Fermentation is highly suitable for large-scale industrial production and is widely used in the pharmaceutical, food, and biofuel industries.
7. What are the oxygen requirements for Submerged Fermentation?
Submerged Fermentation typically requires a high oxygen supply, as the production of many target products depends on aerobic metabolism.
8. Does Submerged Fermentation require strict pH control?
Yes, pH is a critical factor affecting fermentation efficiency. It must be strictly controlled to ensure optimal microbial growth and product formation.
