Many labs and industries use bioreactors, yet users may not fully understand how they work or how to maintain them for proper results. These machines are complex and fascinating, and our guide will share essential information you need to know to better understand them.
What Is a Bioreactor?
A bioreactor is a vessel that facilitates a controlled, stable environment where microorganisms and similar biological components can grow. This process is essential for cultivating certain biological reactions and chemicals. Cells can only work properly in a conducive environment, and bioreactors create these environments by controlling temperatures, balancing pH, creating a sufficient gas supply and providing agitation. Some bioreactors also supplement nutrients, depending on their setup.
Different Types of Bioreactor Processes
While all bioreactors serve the same purpose, their specific functions can differ. The variety of bioreactor process types allows labs to select the bioreactor that best meets their needs. These are the three main types of bioreactor processes:
- Batch: Batch processes don't provide any nutrients during the biological process, aside from control elements added at the beginning of the process. This type of bioreactor allows for continuous use until the cells have consumed all nutrients. They're ideal for experiments where results are needed quickly, but their downside is that they yield limited products.
- Fed-batch: Unlike batch processes, fed-batch processes involve regularly adding nutrient feeds during the bioprocess to prevent them from being depleted. This process often yields better results than batch processes.
- Continuous: Rather than providing nutrients regularly like fed-batch processes, continuous processes provide bioreactors with a continuous flow of nutrients. This process involves adding a new medium to the bioreactor while simultaneously removing the same medium, creating a steady environment.
Other options include semicontinuous and perfusion processes. Choosing the right bioreactor depends on the desired end goal. Each option has advantages and considerations, which you should assess to determine which one will yield the desired results.
What Are Bioreactors Used For?
Bioreactors often play critical roles in industrial environments and research-heavy industries. They're frequently used in pharmaceuticals since they can assist in gene therapy and other medical advancements.
Bioreactors can also benefit the food and beverage industries, specifically dairy products and wine production, as they aid fermentation. Some other common uses of bioreactors include producing antibiotics and vaccinations and treating wastewater.
6 Key Components of Bioreactors
Now that you have a better understanding of bioreactors and how labs can utilize them, it's time to examine their different components.
1. Vessel
A bioreactor's vessel is one of its most essential parts. This structure holds the cell medium and affects heat, oxygen and mixing efficiency, and is necessary for biological reactions to occur. These components are commonly made of plastic, stainless steel or glass, depending on their purpose. Stainless steel is generally recommended as it's durable, easy to clean and can withstand corrosion.
Bioreactor vessels come in many sizes, ranging from small enough for lab use to large enough to contain hundreds of liters. Usually, vessels are cylindrical, but they can also be spherical or conical.
2. Agitator
The agitator is the mechanical part that mixes the components in a bioreactor's vessel. It distributes nutrients, temperature and oxygen evenly throughout the biological components contained in the bioreactor. Ensuring all particles receive the same treatment helps create stable results and yields a better end product.
One of the most common types of agitator is an impeller, which consists of blades attached to a motor on the lid. The motor transports nutrients to the cells and removes waste products.
3. Sparger
Spargers, or air inlets, add oxygen to the culture medium to aerate it. They're designed for optimal gas exchange thanks to the porous materials allowing sufficient airflow.
They work by producing bubbles that are broken down to allow for easy dispensing across the medium, which aids in creating an ideal, stable environment for bioprocesses.
4. Temperature Control
Because bioreactors are used for biological and chemical processes, temperature control is essential. Fluctuations in temperature could affect the quality of the final product.
Some ways to control a bioreactor's temperature include:
- Heat exchangers: Items like coils exchange heat and can be used to control the temperature in a bioreactor.
- Temperature jackets: Heating or cooling jackets contain temperature control fluids, thus regulating the temperature.
- Direct temperature: Electrical heaters or coolers can also manage the bioreactor's temperature if placed directly in the environment.
5. pH Monitoring Sensor
Monitoring sensors can detect pH levels and provide real-time data to give better insight into the bioreactor's internal environment. These sensors can also connect to control systems to allow lab technicians more control over pH levels. pH monitors can add an acid or base to the medium to keep the pH within the appropriate range.
Overall, pH sensors help manage and optimize bioreactors to achieve the desired results.
6. Foam-Control System
While foam in a bioreactor is normal, it's important to remove excess foam and prevent foam buildup. Excess foam can block the exhaust gas filter. To prevent this, bioreactors contain foam sensing and foam control systems. Foam sensors detect when levels are too high, activating the foam control system to reduce the foam.
How to Maintain a Bioreactor
Many industries rely on bioreactors for vital processes, and proper maintenance is essential to keep them functioning properly. When your lab equipment performs as expected, you can increase efficiency and productivity. You can maintain your bioreactor with these tips:
- Sterilize the bioreactor: If bioreactors aren't sterilized properly and often, they could become contaminated, which could damage their biomaterials. All components of a bioreactor need to be sterilized with steam. Filters help sterilize air and gas. Chemical sterilization is a popular choice, but autoclaves and sterilization-in-place systems can make sterilization easier and more effective.
- Conduct regular maintenance: If a bioreactor component has a problem, it's always best to address it immediately to prevent further damage. Schedule regular maintenance checks and servicing to catch problems as soon as possible and ensure the equipment is kept in working order.
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