Bioreactor Design

We design the ideal fermenter for your process.

Design of bioreactor systems

Thanks to its extensive experience with microbial production techniques, Vogelbusch is well acquainted with the differing requirements of designing bioreactors. Besides its specific aeration systems Vogelbusch has the expertise in selecting the appropriate components and proven know-how, to run fermentations stable over longer periods.

A multitude of process and apparatus solutions are available for your specific applications, including aerobic and anaerobic, sterile and non-sterile, batch and continuous, as well as single fermenter and fermenter cascade solutions.

2 bioreactor design
Customized bioreactor systems

Vogelbusch can take an idea from concept to full implementation. We develop the framework of a process based on the client’s lab or pilot plant results.

The appropriate fermentation system is selected to align best with the individual process requirements. 

Vogelbusch also provides technical solutions for associated processes such as media preparation, downstream processing and auxiliary systems.

From lab to production scale

Specialised in upscaling biotechnological processes for the client, Vogelbusch executes projects on the basis of own and customers’ lab or pilot plant results. Based on individual process requirement the appropriate fermentation system and downstream operations are selected.

For the construction of facilities, we 

  • establish detailed specifications of processing equipment and auxilliary facilities, and can provide operating and utility requirements
  • deliver key equipment or turnkey
  • monitor assembly and implementation
  • train personnel
Selection criteria

For best performance a fermentation system is selected to fit process parameters (oxygen and nutrient supply, temperature, pH value, etc.) and considers sensitivity to mechanical stress. 

Further subjects of consideration are particular process requirements such as dissolved oxygen concentration, sterility, permissible concentration gradients or production scale. And we keep an eye on the overall economy of the plant, including investment and operating costs.

Our references for bioreactors are

Yeast plant in Ahvaz
RAZI YEAST & ALCOHOL Co. - Ahvaz, Iran

Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from cane molasses. Production in the yeast plant started in 2009, since manufacturing 32,000 kg per day of high quality instant active dry...

Citric Acid Plant in Kermanshah
KIMIA GHARB GOSTAR Industries Co. - Kermanshah, Iran

The plant has a capacity of 36 tons per day and is the first citric acid plant built in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either of the two commercially available forms of...

4 YeastFermenter
Yeast fermenter in Malmö
SPECIAL YEAST AB - Malmö, Sweden

The utilization of a hydrolysate made from bakery waste was the object of the order by Special Yeast. The process for this novel feedstock was developed and implemented, including supply of the aeration system. The unit has a capacity of 9,000 kg/d and was started up in 2006.

4 YeastAerator
Yeast fermenter in Hamburg
DEUTSCHE HEFEWERKE (now OHLY) - Hamburg, Germany

DHW of Hamburg decided to convert an existing fermenter to the Vogelbusch aeration system. The given situation required the redesign of the drive and included engineering and supply of the complete aerator system. The reconstructed fermenter has a capacity of 27,000 kg per day of baker’s yeast made from beet molasses....

Yeast fermenter in Nuremberg
DEUTSCHE HEFEWERKE - Nuremberg, Germany

DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building. Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system including drive, mash pumps and heat exchangers). The fermenter is designed for 25,000 kg of baker's yeast per day made...

4 YeastFermenter
Yeast fermenter in Osaka

To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering and supply of key equipment (aeration) for an additional yeast fermenter. The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up was...

Citric Acid Plant near Cairo
CITRO MISR Co. - 10th of Ramadan City, Egypt

Raw sugar from local production was the substrate of choice for Citro Misr Co. of Egypt. This raw material required a new approach in the fermentation process to assure the economic feasibility of the plant. The spore cultivation was adapted and the fructose utilization was optimized for the substrate. Products include...

4 gsonek0
Vinegar fermenter in Austria
GSONEK GmbH - Laa an der Thaya, Austria

Supply of a vinegar fermenter type 1200 including IP-8 self priming aeration with a daily capacity of 15,000 liter (10%) for processing pure ethanol and grape and apple wine. The unit, originally set up in 1998, was later acquired by Mautner Markhof and integrated in their Vienna production facilities.


Skid-mounted system for recovery of ethanol
01 Jun 2017

Article on ethanol drying system published in Biofuels International Magazine.