Fermenters are classified into single-layer and double-layer types, with the main difference being the cooling method. Single-layer fermenters use an internal coil for cooling, ensuring even temperature distribution but making cleaning difficult. Double-layer fermenters use an external jacket, which is easier to clean but more expensive and slightly less efficient in cooling.
Fermenters are equipped with a two-stage filtration system: the primary filter removes large particles, while the sterile precision filter requires regular sterilization to maintain aseptic conditions. More filtration stages do not necessarily mean better performance, as increased filter resistance can cause pressure loss. Excessive steam pressure drop during sterilization may lead to incomplete sterilization, while increasing inlet pressure can exceed the filter’s tolerance.
Fixed fermenters require direct steam sterilization. Due to prolonged steam exposure, significant changes in liquid levels occur during the sterilization and cooling process. It is recommended that, if possible, companies preheat water to above 100°C and use a metered liquid transfer system with flow meters to ensure consistent liquid levels in the fermenter.
Many companies still rely on manual mixing and feeding, which is inefficient. It is advisable to use a dedicated mixer: pre-measured ingredients can be added and automatically mixed to uniformity. The liquid can then be transferred in precise quantities to the designated fermenter through a flow-metered pipeline.
After sterilization, water cooling is used to lower the fermenter’s temperature from 121°C to 25°C, requiring at least five times the fermenter’s volume in water, depending on the inlet water temperature. Companies are encouraged to implement a heat recovery system by installing hot and cold water tanks. Initially, high-temperature return water enters the hot water tank, and once it reaches the set threshold, it is redirected to the cold water tank, which is equipped with a cooling system. This method conserves water, allows hot water to be reused for the next batch, reduces steam consumption, and improves overall efficiency.
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