Fermentation Scale up of fermentation Steps in scale up Scale up fermentation process Optimizing scale up of fermentation process Rules followed while doing scale up Studies carried out during scale up Reference

2.  Fermentation
 Definition
 Importance of scale up studies
 Steps in scale up
 Scale of fermentation
process(Large scale, Small
scale& Pilot scale)
 Optimizing scale up of
fermentation process
 Rules followed while doing
scale up
 Studies carried out during
scale up
 References
CONTENTS

3. FERMENTATION:
 Fermentation is a metabolic process that
produces chemical changes in organic
substrates through the action of enzymes.
 EXAMPLES: Yeast perform fermentation
to obtain energy by converting sugar into
alcohol.
HISTORY OF FERMENTATION:
 Louis pasteur became the first scientist
to study fermentation.
 He showed that lactic acid fermentation is
caused by living organisms.

4. DEFINITION:
 Scale up of a fermentation process is to
demonstrate fermentation production
at large scale resulting in the same
productivity and quality as that
developed at small scale.

5. IMPORTANCE OF SCALE UP STUDIES:
 More important during scale up exercises is
that we trying to build industrial size
fermentor capable (or) close of producing the
fermentation products as efficient as those
produced in small scale fermentors.
 It must be appreciated as the size of
fermentation increases during scale up
various parameters measured might not
show a predictable linear co-relationships.
Certain parameters changes. Some remained
constant. Some parameters need to be
modified & adjusted during scale up studies.

6. STEPS IN SCALE UP:
 Define product economics based on
projected market size & competitive selling &
provide guidance for allowable manufacturing
costs.
 Conduct laboratory studies and scale-up
planning at the same time.
 Define key rate- controlling steps in the
proposed process.
 Conduct preliminary larger-than-laboratory
studies with equipment to be used in rate-
controlling step to aid in plant design.

7. STEPS:
 Design and construct a pilot plant including
provisions for process and environmental
controls, cleaning and sanitizing systems,
packaging and waste handling systems, and
meeting regulatory agency requirements.
 Evaluate pilot plant results (product &
process) including process economics to
make any corrections and a decision on
whether or not to proceed with a full scale
plant development.

8. SCALE UP OF FERMENTATON PROCESS:

9. LARGE -SCALE FERMENTATION:
 Large- scale fermentations are utilized to
create massive quantities of ethanol which
are used for food production, alcohol
production, and even gasoline production.
 Yeast is the microorganisms which is used
for a large scale production of alcohol.

10. SMALL SCALE FERMENTATION:
 Small scale fermeter are same as large
fermenter(bioreactor).
 They are 2 types: Bench scale & lab scale
system.
 They are small but highly automated and
customized for the application.
 They can be lab as CSTR / autoclave fixed,
fixed on fluidized bed reactor application.

11. PILOT SCALE FERMENTATION:
 A pilot scale fermenter is a small industrial
system, which is operated to generate
information about the behavior of the system
for use in design of larger facilities.
 Pilot plant is a relative term in the sense that
plants are typically smaller than full scale
production plants, but are built in a range of
sizes.

12.  Various modeling methods are used
including
 Chemical similitude studies
 Mathematical modeling
 Finite elemental analysis
 Computational fluid dynamics
 1) Chemical similitude studies:
 Computer aided modeling and simulations in
the development, intergration optimization of
the industrial process.

13.  2) Mathematical modeling:
 Mathematical modeling is the process of using
various mathematical structures – graphs,
equations, diagrams, scatter plots and so forth-
to represent real world situations.
 3) Finite elemental analysis:
 FEA is a computerized method for predicting
how a product reacts to real – world forces,
vibration, heat, fluid flow and other physical
effect.
 It shows whether a product will break, wear out,
(or) work the way it was designed.

14.  4) Computational fluid dynamics:
 CFD is the use of applied mathematics,
physics and computational software to solve
& analyze problems that involves fluid flows.

15. OPTIMIZING SCALE-UP FERMENTATION
PROCESS:

17. RULES FOLLOWED WHILE DOING SCALE-UP:
 There are a few rules of the thumb followed when
doing scale up studies such as:
1 ) Similarity in the geometry and configuration of
fermentors used in scaling up.
2 ) A minimum of three or four stages of increment
in the scaling up of the volume of fermentation
studies.
3 ) Each jump in scale should be by a magnitude
power increase & not an increase of a few litre
capacity. Slight increase in the working volume
would not yield significant data for scale up
operation.

18. STUDIES CARRIED OUT DURING SCALE UP:
 Inoculum development
 Sterilization establishing the correct
sterilization cycle at larger loads
 Environmental parameters such as nutrient
availability, pH, temperature, dissolved
oxygen, dissolved carbon dioxide.
 Shear conditions, foam production

19. REFERENCES:
S. N0 BOOK NAME AUTHOR’S
NAME
PUBLICATI
ON NAME
YEAR
1. BOOK OF
BIOTECHNOLOGY
SATYANARAYAN
A U.
2010
2. PRINCIPLES OF
FERMENTATION
TECHNOLOGY
PETER F.
STANBURY,
ALLAN
WHITAKER,
STEPHEN
J.HALL
FIRST EDITION 1984
3. MANUAL OF
INDUSTRIAL
MICROBILOGY
AND
BIOTECHNOLOGY
ARNOLD L.
DEMAIN, JULIAN
E. DAVIES,
RONALD M.
ATLAS
MORE EDITION 1999