Fermentation

General

Lactosan Microbial Additives has two complete fermentation lines, which are managed with the process control system. The total capacity of fermentation volume is 25,000l. On one side a 10,000l main stage fermenter follows the 1,000l pre-fermenter and on the other side a 15,000l fermenter is located after a 2,000l pre-stage fermenter. The plant is made of fully sterilisable stainless steel. Three dosage vessels enable the timely controlled fedbatch production.

For each bacterial strain an ideal process is developed and the parameters for this strain-specific formula are then programmed into the control system. Thereby the consistent high quality of production is assured. All raw materials used for the process are tested for their specifications and the regulations defined in a risk analysis are performed for each delivery batch.

Further Steps

The mixture of raw materials to the fermentation medium takes place in a room, which is separated from the plant. The raw materials processed to dough are then pumped into the Lactosan Microbial Additives plant and sterilised directly in the fermenter. The bacterial strains are stored as glycerine stock at -80°C.

Pre-Fermentation

From each strain a master cell bank is created and tested on purity, identity and growth behaviour. With a vial of this master cell bank the pre-cultivation step is performed in bottles or flasks. With these the preliminary stage of the fermentation process is started. Samples of all stages are drawn, tested and retainer samples are stored. A control of the fermentation temperature, the pH value and oxygen and nutrient content can be perfectly implemented.

Capacities

 

Total Capacity Main Stage Fermenter Preliminary Stage
25000 l 10000 l 1000 l
15000 l 2000 l

Special Features of the Plant

The plant features a NaOH pipe system for pH control and can also be fed with NH3, KOH or acids from external vessels. The dosage with air, N2 or special gas mixtures is possible at any time. After each production automatic CIP/SIP cleaning steps are performed. For each fermentation a batch protocol is kept and the data points of the parameters from the process control system and the analysis approval complement this after the batch is completed.