Scale up of fermentation

Definition◦ Scale up studies refers to the act of using results

obtained from laboratory studies for designing a prototype and a pilot plant process; construction a pilot plant and using pilot plant data for designing and constructing a full scale plant or modifying an existing plant.

Scale up

Scale up

Scale up

A pilot plant allows investigation of a product and process on an intermediate scale before large amounts of money are committed to full-scale production.

It is usually not possible to predict the effects of a many-fold increase in scale.

Scale up studies are studies carried out at the laboratory or even pilot plant scale fermentors to yield data that could be used to to extrapolate and build the large scale industrial fermentors with sufficient confidence it will function properly with all its behaviours anticipated.

Why conduct Scale up Studies?

More important during scale up exercises is that we are 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 and adjusted during scale up studies. The objective is to try to get the same fermentation efficiency as obtained in small scale fermentors at the most economical values.

Importance of scale up studies

There are few crucial studies which will only be answered by carrying it out on the pilot plant such as:

Determining the various operational parameters for optimized oxygen supply to the fermentation process.

Selection of optimum operative modes of the fermentor

Determining the changes in rheological properties and its effect on the fermentation process.

Modeling and formulation of process controls Sensors and controls

Define product economics based on projected market size and competitive selling and 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

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 and process) including process economics to make any corrections and a decision on whether or not to proceed with a full scale plant development

Steps in Scale-Up

INITIAL SCALE UP STUDIES

Most scale up studies are usually carried at different phases involving different scales of fermentors. Preliminary work are carried out at the level of petri dishes and small scale laboratory fermentors to establish whether the process is technically viable, meaning it is possible to produce such fermentation process and the products on the small scale. Additional parameters not provided by petri dishes studies and for more confidence are obtained by carrying further studies using submerged liquid fermentation using various sizes laboratory scale fermentors and even a pilot plant fermentor.

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 up2. A minimum of three or four stages of increment in the scaling up of the volume of fermentation studies. Each jump in scale should be by a magnitude or power increase and not an increase of a few litres capacity. Slight increase in the working volume would not yield significant data for scale up operation

Rules followed while doing scale-up

Evaluating the results of laboratory studies and making product and process corrections and improvements

Producing small quantities of product for sensory, chemical, microbiological evaluations, limited market testing or furnishing samples to potential customers, shelf-live and storage stability studies

Determining possible salable by-products or waste stream requiring treatment before discharge

Providing data that can be used in making a decision on whether or not to proceed to a full-scale production process; and in the case of a positive decision, designing and constructing a full-size plant or modifying an existing plant

A pilot plant can be used for

1. Inoculum development2. Sterilization establishing the correct sterilization cycle at larger loads3. Environmental parameters such as nutrient availability, pH, temperature, dissolvedoxygen, dissolved carbon dioxide,4. Shear conditions, foam production

Studies carried out during scale up

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