title: Design and installation of a next generation pilot scale fermentation system.
abstract: Four new fermenters were designed and constructed for use in secondary metabolite cultivations, bioconversions, and enzyme production. A new PC/PLC-based control system also was implemented using GE Fanuc PLCs, Genius I/O blocks, and Fix Dynamics SCADA software. These systems were incorporated into an industrial research fermentation pilot plant, designed and constructed in the early 1980s. Details of the design of these new fermenters and the new control system are described and compared with the existing installation for expected effectiveness. In addition, the reasoning behind selection of some of these features has been included. Key to the design was the goal of preserving similarity between the new and previously existing and successfully utilized fermenter hardware and software installations where feasible but implementing improvements where warranted and beneficial. Examples of enhancements include strategic use of Inconel as a material of construction to reduce corrosion, piping layout design for simplified hazardous energy isolation, on-line calculation and control of nutrient feed rates, and the use of field I/O modules located near the vessel to permit low-cost addition of new instrumentation.
authors.affiliation: Bioprocess Research and Development, Merck Research Laboratories, P.O. Box 2000, Rahway, New Jersey 07065, USA.
authors.forename: B
authors.initials: B
authors.lastname: Junker
authors.forename: T
authors.initials: T
authors.lastname: Brix
authors.forename: M
authors.initials: M
authors.lastname: Lester
authors.forename: P
authors.initials: P
authors.lastname: Kardos
authors.forename: J
authors.initials: J
authors.lastname: Adamca
authors.forename: J
authors.initials: J
authors.lastname: Lynch
authors.forename: J
authors.initials: J
authors.lastname: Schmitt
authors.forename: P
authors.initials: P
authors.lastname: Salmon
mesh_terms: D000465:Algorithms; D019149:Bioreactors / Q000382:microbiology*; D018929:Cell Culture Techniques / Q000295:instrumentation* / Q000379:methods; D004867:Equipment Design; D019544:Equipment Failure Analysis; D005246:Feedback; D005285:Fermentation / Q000502:physiology*; D010865:Pilot Projects; D011786:Quality Control; D012371:Robotics / Q000295:instrumentation* / Q000379:methods; D018511:Systems Integration