Top 10 Bioreactor Brand & Manufacturers

What is a Bioreactor?

A bioreactor is a vessel or a system designed to support a biologically active environment. It provides the necessary conditions such as temperature, pH, oxygen supply, and agitation to facilitate the growth and metabolism of cells, microorganisms, or enzymes for the production of biological products. Bioreactors are used in various biotechnological processes including the production of pharmaceuticals, biofuels, vaccines, enzymes, and fermented food and beverages.

History of Bioreactor

The history of bioreactors dates back to ancient times when humans first used fermentation processes to produce food and beverages like beer and wine. However, the modern concept of a bioreactor began to take shape in the 20th century. With the growth of the biotechnology industry and the need for more controlled and efficient biological processes, the design and engineering of bioreactors evolved. Early bioreactors were simple vessels, but as the understanding of microbiology and cell biology advanced, more sophisticated bioreactors with advanced control systems for temperature, pH, and agitation were developed. The development of disposable bioreactors in recent decades has also had a significant impact, allowing for more flexible and cost - effective production in some applications.

Purpose of Bioreactor

• Pharmaceutical Production: In the pharmaceutical industry, bioreactors are used to produce therapeutic proteins, antibodies, and vaccines. For example, mammalian cell cultures are grown in bioreactors to produce monoclonal antibodies used in cancer treatment and other diseases. The controlled environment of the bioreactor ensures the proper folding and post - translational modifications of these complex proteins.
• Biofuel Production: Bioreactors play a crucial role in the production of biofuels such as ethanol and biodiesel. Microorganisms are cultured in bioreactors to convert biomass (like corn starch or sugarcane juice) into biofuels through fermentation or other metabolic processes. This provides a renewable energy source alternative to fossil fuels.
• Food and Beverage Fermentation: In the food industry, bioreactors are used for the production of fermented products such as yogurt, cheese, and sauerkraut. The growth of lactic acid bacteria and other microorganisms in a controlled bioreactor environment helps in achieving consistent product quality and flavor.
• Enzyme Production: Bioreactors are used to produce industrial enzymes. Microorganisms are cultivated to secrete enzymes that are used in various industries such as detergents (for example, proteases and lipases), textile (amylases), and food processing (pectinases). The bioreactor conditions are optimized to maximize enzyme production and activity.

Principle of Bioreactor

Cell Growth and Metabolism Support: Bioreactors provide an environment that mimics the natural conditions required for cell growth and metabolism. They supply nutrients such as sugars, amino acids, and vitamins to the cells or microorganisms. The agitation system in the bioreactor ensures proper mixing of the medium and cells, which helps in the uniform distribution of nutrients and oxygen. Oxygen is supplied through aeration systems, and carbon dioxide produced by the cells is removed. The temperature and pH are carefully controlled using heating/cooling systems and pH - regulating agents to maintain the optimal physiological conditions for the biological entities.
Process Monitoring and Control: Bioreactors are equipped with sensors to monitor key parameters such as temperature, pH, dissolved oxygen, and cell density. These sensors send signals to a control system that adjusts the operating conditions of the bioreactor. For example, if the dissolved oxygen level drops below a set point, the aeration rate can be increased. This closed - loop control system helps in maintaining the stability and productivity of the biological process.

Features of Bioreactor

• Controllability: High - quality bioreactors offer precise control over environmental conditions such as temperature (with an accuracy of a few degrees Celsius), pH (to within a narrow range), and dissolved oxygen levels. This control is essential for optimizing cell growth and product formation.
• Scalability: Bioreactors can be designed and scaled up from small laboratory - scale units to large - scale industrial reactors. The scalability allows for the transition from research and development to commercial production. The design principles and operating conditions can be adjusted to maintain similar performance at different scales.
• Versatility: They can be used for a wide variety of biological processes involving different types of cells (bacterial, yeast, mammalian), microorganisms, and enzymes. The bioreactor can be configured to support aerobic or anaerobic processes depending on the requirements of the biological entities.[!--empirenews.page--]
• Material Compatibility: Bioreactors are usually made of materials that are compatible with biological systems and do not leach harmful substances. Stainless steel and certain plastics are commonly used materials. The interior surfaces are often designed to be smooth to prevent the accumulation of cells or debris and to facilitate cleaning and sterilization.

Types of Bioreactor

• Stirred - Tank Bioreactor: This is the most common type. It consists of a cylindrical tank with a stirrer or impeller that provides agitation to mix the cells and nutrients. The stirrer helps in the transfer of oxygen and nutrients and also in the removal of waste products. Stirred - tank bioreactors are suitable for a wide range of aerobic and anaerobic processes and can be easily scaled up.
• Air - Lift Bioreactor: In an air - lift bioreactor, the mixing and circulation of the medium are achieved through the injection of air or gas. The air bubbles rising through the liquid column cause the liquid to circulate. This type of bioreactor is often used for processes where gentle agitation is required, such as the cultivation of shear - sensitive cells.
• Packed - Bed Bioreactor: Packed - bed bioreactors contain a solid matrix or packing material on which the cells or enzymes are immobilized. The substrate solution is passed through the packed bed, and the biological reactions occur on the surface of the immobilized cells or enzymes. This type is useful for continuous - flow processes and enzyme - catalyzed reactions.
• Fluidized - Bed Bioreactor: In a fluidized - bed bioreactor, the solid particles (usually with attached cells or enzymes) are suspended in a fluidizing medium. The fluidization provides good mass transfer and mixing. It is often used for processes that require high mass - transfer rates and rapid reaction kinetics.

Precautions for using Bioreactor

• Sterilization: Before use, the bioreactor and all associated equipment such as pipes, valves, and sensors must be thoroughly sterilized to prevent contamination. Steam sterilization is a common method. Any contamination can lead to the growth of unwanted microorganisms and can affect the productivity and quality of the desired biological process.
• Monitoring and Maintenance: Regularly monitor the key parameters such as temperature, pH, and dissolved oxygen. The sensors should be calibrated regularly to ensure accurate readings. The mechanical parts such as the stirrer and pumps should be maintained to ensure proper operation. Any malfunction of these components can disrupt the biological process.
• Cell and Medium Compatibility: Ensure that the bioreactor materials and operating conditions are compatible with the cells or microorganisms being cultured. Some cells are sensitive to shear forces, so the agitation rate should be adjusted accordingly. The medium composition should be optimized to meet the nutritional requirements of the cells.
• Scale - up Considerations: When scaling up a bioreactor process from laboratory to industrial scale, consider factors such as mixing efficiency, mass transfer, and heat transfer. The performance of the process may change due to differences in the scale, and appropriate adjustments need to be made to maintain the same productivity and product quality.

Things to consider when purchasing Bioreactor

• Process Requirements: Consider the type of biological process you will be conducting. For example, if you are culturing shear - sensitive cells, an air - lift or a fluidized - bed bioreactor might be more suitable. If you need a versatile system for a variety of processes, a stirred - tank bioreactor could be a good choice.
• Scale and Capacity: Determine the volume and scale of production you require. Bioreactors come in a wide range of sizes, from small bench - top units for research purposes to large - scale industrial reactors. Make sure the bioreactor can be scaled up or down as your needs change.
• Control and Monitoring Features: Look for a bioreactor with advanced control systems for temperature, pH, dissolved oxygen, and other parameters. The ability to accurately monitor and control these variables is crucial for successful biological processes. Consider the availability of data - logging and remote - monitoring capabilities.
• Material and Construction Quality: Check the materials used in the bioreactor's construction. They should be of high quality, durable, and biocompatible. Stainless steel is a popular choice for its strength and resistance to corrosion, but other materials like certain plastics may also be suitable depending on the application.
• Cost and Budget: Bioreactors vary in price depending on their type, size, and features. Set a budget and look for a bioreactor that offers the best combination of performance and cost - effectiveness. Consider not only the initial purchase cost but also the cost of installation, operation, maintenance, and any associated accessories such as pumps and sensors over the life of the bioreactor.[!--empirenews.page--]

Terms of Bioreactor

• Cell Density: The number of cells per unit volume in the bioreactor. Monitoring cell density is important for understanding the growth phase of the cells and for optimizing the production process. It can be measured using methods such as optical density or cell counting.
• Dissolved Oxygen (DO): The amount of oxygen dissolved in the liquid medium of the bioreactor. Maintaining an appropriate DO level is crucial for aerobic biological processes. It is usually measured in milligrams per liter (mg/L) or as a percentage of saturation.
• Agitation: The process of mixing the contents of the bioreactor, usually achieved through a stirrer or by the injection of gas. Agitation helps in the distribution of nutrients, oxygen, and cells and also in the removal of waste products.
• Immobilized Cells/Enzymes: Cells or enzymes that are attached to a solid support material in the bioreactor. Immobilization can increase the stability and reusability of the cells or enzymes and can also affect the reaction kinetics and mass - transfer characteristics of the process.