comparable projects actual...

COMPARABLE_PROJECTS_ACTUAL_ES.doc Página 1 de 38

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DOCUMENTO ADICIONAL

PROYECTOS recientemente ejecutados por

BIOPROCESS TECHNOLOGY

28670 Villaviciosa de Odón-Madrid e-mail: [email protected]

www.bioprocess.es

C/ Segura 9 Telf. : 916 16 86 05 Fax : 916 16 80 02


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INTRODUCCION:

Bioprocess Technology es una empresa especializada en el campo de la

biotecnología e industrias afines. Con una experiencia de mas de 20 años, el

departamento de Ingeniería y desarrollo posee el “Know How” necesario para la

elaboración de la ingeniería y re-ingeniería de todas las etapas relacionadas con el

Proceso Biotecnológico; desde el diseño de la instalación hasta la fabricación,

instalación y puesta en marcha de plantas de proceso a nivel industrial como de

laboratorios de I+D.

Por su reconocimiento en el mercado y la capacidad de sus instalaciones,

actualmente ofrecemos asesoramiento en la mejora y escalado de procesos

biotecnológicos existentes así como el servicio de fermentación microbiana y

procesos de cultivos en nuestras instalaciones.

Es importante mencionar que entre las máximas de Bioprocess Technology se

destacan el aseguramiento de la calidad a todos los niveles cumpliendo con las

más exigentes normas a nivel nacional e internacional, tanto así como la robustez

de todo los componentes integrados en cada instalación.


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PROJECTS LIST: AÑO CLIENTE TITULO DETALLES PRINCIPALES

629.000,00 €

Inés del Campo

(+34) 948 252 800

2011-2012 CENER Ingeniería, fabricación y puesta en marcha de

una Unidad de Fermentación compuesta por

fermentadores de 1.000, 3.000 y 6.000 litros,

y un depósito de dilución de 13.000 litros.

Actualmente ejecutándose. [email protected]

76.500,00 €

Eva Navascuez

(+34) 926 550 200

2011-2012 AGROVIN Instalación para producción, consistente en un

birreactor de 100 litros y una unidad de

ventilación con filtros HEPA.


530.000,00 €

Antonio Fernandez

(+34) 987 849 200

2011-2012 Instituto Biomar Ingeniería, diseño, fabricación y puesta en

marcha de una planta de fermentación y

downstream con requerimientos ATEX con

una capacidad total de 4000 litros/día.


220.000,00 €

Juan Ramón Muñoz

(+34) 967 599 361

2011 ZURKO

BIOREASEARCH

Instalación de investigación y producción,

consistente de dos biorreactores de 100 litros

cada uno y un generador de vapor limpio.

[email protected]

2011 CSIC-Consejo Suministro e Instalación de una planta piloto 105.000,00 €


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Teresa Requena

(+34) 910 017 900

Superior de

Investigaciones

Científicas.

INSTITUTO DEL FRIO

de simulador gastrointestinal para

investigación (SIMGI).

[email protected]

573.000,00 €

Heleen De Wever

+32-14-33 69 32

2010-2011 VITO – EUROPEAN

SPACE AGENCY

BELISSIMA Project COMPARTMENT I.

Planta piloto en el entorno del proyecto

EUROPEO MELISSA.

[email protected]

480.000,00 €

Jorge Estefanel

(+34) 986 330 400

2010-2011 CZ VETERINARIA Planta de producción de vacunas, consistente

en cuatro reactores de inactivación de

capacidad 2500 litros y uno de 500 litros.

[email protected]

760.000,00 €

Jorge Estefanel

(+34) 986 330 400

2009-2010 CZ VETERINARIA Planta de producción de vacunas, consistente

en dos fermentadores de 2500 litros cada uno,

uno de 500 litros y uno de 250 litros.

[email protected]

285.000,00 €

Francis SMAL

2009 SNC LAVALIN – UAB –

AGENCIA ESPACIAL

EUROPEA

Proyecto MELiSSA COMPARTIMENTO III.

(+32) 2 643.15.37


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[email protected]

240.000,00 €

Antonio Fernandez

(+34) 987 849 200

2008-2009 Instituto Biomar Planta de fermentación para producción de

metabolitos de interés industrial a partir de

microorganismos de origen marino.

[email protected]

220.000,00 €

Jorge Estefanel

(+34) 986 330 400

2008-2009 CZ VETERINARIA Sistema para cultivo de células animales para

producción de vacunas.

[email protected]

195.000,00 €

Aleix Parra

(+34) 93 333 600

2008-2009 SANOFI AVENTIS Laboratorio para preparación de mezclas,

para uso farmacéutico, con certificación

ATEX.

[email protected]

550.000,00 €

Cristina Ramiro de Peñaranda

(+34) 91 371 79 70

2007-2008 Telstar Project 16 Reactores para una planta de producción

de vacunas.

[email protected]

87.000,00 € 2007 Instituto de Recursos

Naturales (IRENA)

Planta piloto para estudio y optimización en

la producción de BIOGAS. Antonio Morán


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(+34) 987 29 18 41

[email protected]

1.800.000,00 €

Francisco Moralejo

(+34) 987 800 800

2007-2008 Laboratorios Syva Planta de producción de vacunas.

[email protected]


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DETALLE DE PROYECTOS EJECUTADOS

En este apartado se puede observar un archivo fotográfico de

equipos / proyectos similares al ofertado.


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CUSTOMER: CENER Location: Pamplonam Province – Spain Year: 2011-2012

TITLE: Production plant, consisting of four reactors from 1.000 to 13.000 litters. Currently

running.

Design, manufacturing, installation and start up of three fermenters and a dilusion vessel for a BioFuel production pilot plant.

This project consists of: 3 Stirred and jacketed bioreactors (6000, 3000 and 1000 litters), manufactured

in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for biofuel industry. It has a special design for treatment of crops with low mechanical stress.

1 General Industrial control panel with touch screen user interface (HMI) where

runs a SCADA application for process supervision, control and data acquisition, and field instrumentation for stirring, temperature, working pressure, media pH, O2 and DO2 concentration measurement and control.

3 Sterilization in place automation systems for 3 bioreactors. (SIP), and other

processes based on user-configurable recipes. 1 SCADA software for process supervision, control and data acquisition from a

PC with remote connection via TCP/IP protocol over ETHERNET LAN. 4 Pipe Network units for distribution of fluids and feeding of bio-reactors. 1 Stirred and heated vessel (13000 litters), manufactured in stainless steel AISI

316L, in compliance with all the sanitary and hygienic standards for biofuel industry.

1 Cooling system for the fermentation unit to keep cooling set up.


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CUSTOMER: AGROVIN

Location: Ciudad Real Province – Spain Year: 2011-2012

TITLE: Production plant, consisting of one fermenter of 100 litters and one clean air system

including HEPA filters. Currently running.

Design, manufacturing, installation and start up of one fermenter and a clean air system for a production system of industrial concern.

This project consists of: 1 Stirred and jacketed bioreactor (1x100L), manufactured in stainless steel AISI

316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special design for treatment of bacterial cultures with low mechanical stress.

1 Pipe Network units for distribution of fluids and feeding of bio-reactors.

1 Clean Air System, designed for the total volume of the room where the

bioreactor is going to be located in accordance with the standards for food industry.


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CUSTOMER: Instituto Biomar

Location: León province – Spain Year: 2011-2012

TITLE: Engineering, manufacturing and start up of a fermentation and downstream ATEX

requirements plant with total process capacity of 4000 litres/day. Currently running.

Engineering, design, manufacturing, installation and start up of a fermentation and downstream ATEX requirements plant for FDA certified production.

This project consists of: 1 Multifunction jacketed bio-reactor (1x3500 litters), manufactured in stainless

steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special for cooling and fermentation processes.

1 Cooling System with a special design for using in a bioprocess production

environment. 1 Downstream plant for treatment of fermentation broth. Purification system

including one on line rotary filter, medium recovery reactors, extractor reactors and a thin film evaporator.

Decanting system, consisting of a stirred reactor design for ATEX requirements

environment.


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CUSTOMER: ZURKO BIOREASEARCH

Location: Albacete province – Spain Year: 2011

TITLE: Research and production facility, consisting of two bioreactors 100litros and one

clean steam generator. Recently finished.

Design, manufacturing, installation and start up of two fermentors and a clean steam generator for a production system of researching and industrial production concern.

This project consists of: 2 Stirred and jacketed bio-reactors (2x200), manufactured in stainless steel AISI

316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special design for treatment of bacterial cultures with low mechanical stress.


1 Clean Stem Generator, designed for one bio-reactors, for sterilization and

thermostatization.


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CUSTOMER: CSIC-Consejo Superior de Investigaciones Científicas. INSTITUTO DEL FRIO

Location: Madrid province – Spain Year: 2011

TITLE: Research facility for a gastrointestinal simulator pilot plant (SIMGI). Currently

running.

Research, design, manufacturing, installation and start up of a gastrointestinal Simulator for an official institute of technology.

This project consists of: 1 stomach consisting of two chambers built in glass specially made to simulate

the first phase of the digestive tract. Measurement and control of parameters in real time and set peristaltic behavior.

1 Small intestine consisting of a temperature-controlled jacketed special glass reactor design for simulating the second phase of digestion. Measurement and control of parameters in real time and set peristaltic behavior.

Large Intestine, consisting of 3 jacketed glass reactors to simulate different stages of the third phase of the digestive system. Measurement and control of parameters in real time and set peristaltic behavior.


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CUSTOMER: VITO – ESA Location: Mol – Belgium Year: 2010-2011

TITLE: BELISSIMA Project COMPARTMENT I. Currently running.

Design, manufacture, installation and commissioning of a pilot plant for nitrification of ammonia in MELiSSA project environment.

This project consists of: Compartment I or the liquefying compartment is the collection pool for the

waste produced by the consumer (i.e. feces, urea, paper) as well as the non-edible parts of the higher plant compartment (straw, roots, ..). Its essential task is to anaerobically transform these waste products to NH3, CO2, volatile fatty acids (VFA) and minerals.

Intermediate fermentation products have more value for life support than the end product methane because they can be used more readily for edible biomass production. Such a partial anaerobic digestion can be obtained by inhibiting methanogenic activity. In MELiSSA, this is achieved by operating the bioreactor under slightly acidifying conditions. For biosafety reasons, as well as to improve degradation efficiency, compartment I is operated under thermophilic conditions at 55°C. For an efficient separation of the fermentation products from the biosolids, the reactor is equipped with an ultrafiltration membrane unit. Thus, it is conceptually a sidestream acidifying anaerobic membrane bioreactor. Fecal material and non-edible plant parts provide compartment I with a continuous influx of new micro-organisms and thus determine the final microbial community composition.


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CUSTOMER: CZ VETERINARIA

Location: Vigo province – Spain Year: 2010-2011

TITLE: Vaccine production plant, consisting of four reactors 2500litros and one of 500 litters.

Design, manufacturing, installation and start up of a vaccine production system of veterinary industrial concern.

This project consists of: 5 Stirred and jacketed bio-reactors (4x2500 and 1x500 litters), manufactured in

stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special design for treatment of crops with low mechanical stress.

1 Sterilization in place system for 5 bio-reactors.(SIP)


2 Cold and Heat exchangers, designed for each one of bio-reactors, for

thermostatization.


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TITLE: Production plant, of pharmaceuticals, by fermentation with two 2500 litters, a 500

litters and a 250 litters reactors.

Design, manufacture, installation and commissioning of new fermentation

plant for vaccines developing in the veterinary industry.

This project consists of: 4 Stirred and jacketed reactors (2x2500, 500 and 250 litters), manufactured in

stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special design for treatment of crops with low mechanical stress.

4 Industrial control panel with touch screen user interface (HMI) where runs a

SCADA application for process supervision, control and data acquisition, and field instrumentation for stirring, temperature, working pressure, media pH, O2 and DO2 concentration measurement and control.

4 Sterilization in place automation systems for 5 bio-reactors. (SIP), and other

processes based on user-configurable recipes. 1 SCADA software for process supervision, control and data acquisition from a

PC with remote connection via TCP/IP protocol over ETHERNET LAN. 4 Pipe Network units for distribution of fluids and

feeding of bio-reactors.


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CUSTOMER: SCN LAVALIN – UAB - ESA

Location: Barcelona province – Spain Year: 2009

TITLE: MELiSSA Project COMPARTMENT III.

Design, manufacture, installation and commissioning of a pilot plant for nitrification of ammonia in MELiSSA project environment.

This project consists of: The nitrifying compartment or

compartment III, as its main objective the conversion of ammonia to nitrates in a biological nitrification bioreactor. It has carried out the operation of biological nitrification in bio films in fixed bed reactors, for which they have used a pilot scale reactor (approximately 8 L of total volume), and three laboratory-scale reactor (0.65 mL total volume) with bacteria Nitrosomonas europaea (ATCC 19718) for the oxidation of ammonia and nitrite oxidation by Nitrobacter winogradskyi (ATCC 25391) immobilized on polystyrene beads (Biostyr ®).

Within the development of

reactors, the basic instrumentation was implemented and configured the control of the main variables affecting the biotechnology biological nitrification bio film pH, temperature, dissolved oxygen, pressure, level control, etc.


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2 jacketed reactors (2x30 litters), manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for pharmaceutical industry. It has a special design for treatment of crops with low mechanical stress.

1 stirred and jacketed reactor (10 litters),

manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for pharmaceutical industry. It has a special design for the bio-conversion of NH4 + ammonium nitrate NO3.

1 unit for manual Sterilization in place system for all reactors and pipe lines.

Pneumatic control cabinet for centralized control of pneumatic valves through

a pneumatic valve terminal inside of a stainless steel box. Field instrumentation for pH, oxygen, pressure, temperature and dissolved

oxygen measurement. Middle field communication

cabinet for centralize field signals and sending them to the control room.


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Picture #1: 3D view of complete SKID.


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CUSTOMER: Instituto Biomar

Location: Leon province – Spain Year: 2008-2009

TITLE: Fermentation Plant for production of metabolites of industrial interest from

microorganisms of marine origin.

Design, manufacturing, installation and start up of a fermentation facility for metabolite production of industrial concern.

This project consists of: 2 Compressed air production systems.

1 Production system of filtered steam for sterilization.

1 Production system of general use steam.

5 Fermentors (3000, 380, 120, 2 x 40 litters) for micro-organisms culture under

aerobic or anaerobic conditions including “in situ” sterilization capacity. Auxiliary reactors for addition of acid / alkali.

Mixing Reactors units for culture media preparation and treatment.


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1 Filtering system for biomass and broth separation. 1 components extraction system

with the use of solvents. 1 Pipe Network unit for distribution

of fluids and feeding of bio-reactors.

Including 1 SCADA software for

process supervision, control and data acquisition from a PC with remote connection via TCP/IP protocol over ETHERNET LAN.

Picture #1: Top View of a new 3000 litters Fermentor.

Picture #2: Frontal View of a new 3000 litters

Fermentor.


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TITLE: System for animal cell culture for vaccine production.

Design, manufacturing, installation and start up of a vaccine production

system of veterinary industrial concern.

This project consists of: 1 Stirred and jacketed reactors

(2000 litters), manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. It has a special design for treatment of crops with low mechanical stress.

1 Industrial control panel with touch

screen user interface (HMI) where runs a SCADA application for process supervision, control and data acquisition, and field instrumentation for stirring, temperature, working pressure, media pH, O2 dissolved measurement and control.

1 Sterilization in place automation

system for a bio-reactor. (SIP), and other processes based on user-configurable recipes.

1 SCADA software for process supervision, control and data acquisition from a

PC with remote connection via TCP/IP protocol over ETHERNET LAN.


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Picture #1: Commissioning phase of Reactor

project.

Picture #2: Set up phase of field elements

of the system.


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CUSTOMER: SANOFI AVENTIS

Location: Gerona province – Spain Year: 2008-2009

TITLE: Mixtures preparation Laboratory, pharmaceutical uses, with ATEX certification.

Design, manufacturing, installation and start up of an ATEX zone 2 classified

pharmaceutical laboratory. Including 3 reactors for performance of mixtures of acetone powder dissolution (flammable liquid).

This project consists of: 2 Stirred reactors (2 x 200 litters)

including conventional stirrers and ancora type scrapers, with hoppers for powder loading, all the equipments are manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for pharmaceutical industry.

1 Pneumatically stirred (Turrax

type) mobile reactor (80 litters) including a lid with pneumatic lift.

All these reactors include an industrial control panel with touch screen user

interface (HMI) where runs a SCADA application for process supervision, control and data acquisition. The control system allows the automatic execution of process recipes, configurable for the end user. We have included an automatic tank blanketing process by the use of N2 before the loading of ACETONE, and a control system to prevent the formation of explosive atmospheres inside the reactor during operation with acetone.


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Developing of a Clean in Place

system (CIP) for all the reactors. The facility has a pipe, valves and

pumps system for the fluid transfer between the different reactors.

All the equipments included in this facility are in compliance with the 94/9/EC (ATEX95) directive. Picture #1:Mobile Reactor manufacturing.


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CUSTOMER: Telstar Project Location: Caracas province – Venezuela Year: 2007-2008

TITLE: 16 Reactors for vaccine production plant.

Design and manufacturing of 16 reactors for 3 vaccines production lines

(Pertusis, Tetanus y Diphtheria) with automatic control. This project consists of: Design of the supply lines, process fluid and

aids. Design of the lines and methods of transfer

between the different reactors. Design and programming, based on

industrial PLC’s and touch screen user interfaces (HMI) for the “in situ” sterilization processes (SIP) and cleaning in place (CIP) for each of the reactors.

16 reactors manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry.

All the equipments include a control panel with touch screen user interface (HMI) and a control system for stirring speed control and temperature measurement and control, measurement of: process pressure, media pH and liquid level.

It has automated processes for sterilization (SIP) and cleaning (CIP) based on an industrial PLC. Profibus-DP interface for supervision and process data communication to a SCADA master system.


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Pertussis production line 1 Stirred and jacketed reactor (600 litters), for culture media preparation. 1 Stirred and jacketed reactor (200 litters), microfiltration process for the

fermentation product. Diphtheria production line 2 Stirred and jacketed reactors (200 litters), for

culture media preparation. 1 Stirred and mobile reactor (40 litters), for the

transfer of ultrafiltration product to the sterile filtration room.

2 Stirred and jacketed reactors (80 litters) for

the implementation of the stages of concentration and purification of the final product.

1 Stirred and mobile reactor (40 litters), for the

transfer of purified product to the sterile filtration room.

Tetanus production line 2 Stirred and jacketed reactors (200 and

600 litters), for culture media preparation. 1 Stirred and mobile reactor (40 litters),

for the transfer of ultrafiltration product to the sterile filtration room.

2 Stirred and jacketed reactors (80 litters)

for the implementation of the stages of concentration and purification of the final product.

1 Stirred and mobile reactor (40 litters), for

the transfer of purified product to the sterile filtration room.


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Formulation and Filling

1 Stirred and jacketed reactor (200 litters), for media preparation where

antigens are added together. 2 Stirred and jacketed and mobile reactor (375 litters), for the antigen addition,

with transfer of final product to the filling line.


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CUSTOMER: Instituto de Recursos Naturales (IRENA)

Location: Leon province – Spain Year: 2007

TITLE: Pilot plant for the study and optimization in the BIOGAS production.

Design, manufacturing, installation and start up of a pilot plant for studying and

optimization of biogas production from vegetal organic waste fermentation, previously crushed and (partially) liquefied. (High percentage of solid particles of variable size). This project consists of: 3 Stirred and jacketed reactors (cold reactor for waste storage, main

thermostatized fermentor, secondary thermostatized fermentor).

The storage reactor is maintained at 4 ° C with an automatic industrial cooling

system while the fermentors are thermostatically controlled at 37ºC using 2 independent systems of automatic temperature control, which dosed hot water to the thermostatic reactor jackets from electric heaters.


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An automatic control system based on an industrial PLC manages with the

online fermentation process by continuous measurement and control of liquid level. It is transferred from one reactor to the next one (Storage-Reactor> Main-Fermentor> Secondary-Fermentor) by pneumatic cylinders. The system measures and records the volume of gas generated in each of the 2 fermentors.

Including 1 SCADA software for process supervision, control and data acquisition from a PC with remote connection via TCP/IP protocol over ETHERNET LAN.


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CUSTOMER: Laboratorios Syva

Location: Leon province – Spain Year: 2007-2008

TITLE: Vaccine production plant.

Design, manufacturing, installation and start up of an animal vaccine

production facility for the anaerobic and aerobic microorganisms culture with veterinary industrial proposes.

The facility counts with 15

different reactors to complete the different steps of the process: storage tanks, media preparation, media sterilization, fermentation (culture) and dosage to the filling machines.

The plant consists of: 2 Stirred and jacketed reactors (600 and

225 litters) for culture media preparation. Including 1 Instrumentation and electronic systems for stirring speed control, process temperature control and liquid loading control.


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2 Stirred and jacketed reactors (2 x 300 litters) for “in situ” culture media sterilization (SIP), equipped with a transfer system to a Fermentor. Including 1 Instrumentation and electronic systems for stirring speed control, process temperature control and media pH measurement.

1 Stirred reactor (1250 litters), for

intermediate purified water storage (PW) and water for injections (WFI), with transfer to process reactors. Including 1 Instrumentation and electronic systems for stirring speed control and liquid level control.

2 Stirred and mobile reactors (2 x 120 litters), for dosing to the filling machines

line. The reactor is designed for autoclave sterilization. Including 1


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Instrumentation and electronic systems for stirring speed control and liquid level maintenance control.

1 Stirred and jacketed and mobile reactor

(250 litters), for culture media preparation. Including 1 Instrumentation and electronic systems for stirring speed control, process temperature control with a 25,2 KW electrical warming system, media pH measurement and liquid loading control.

4 Stirred and jacketed fermentors/bioreactors (275, 300, 1000 and 3000 litters), for micro-organisms culture under aerobic conditions for industrial production. Including 1 Instrumentation and electronic panel with an HMI tactile Interface control system for stirring speed control and measurement and control of: process temperature, process pressure, media pH and media dissolved oxygen. SCADA software for process supervision, control and data acquisition from a PC with remote connection via TCP/IP protocol over ETHERNET LAN.


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Picture #1: Fermentor 275

litters.

Picture #2: Fermentor 300

litters.

Picture #3: Fermentor

3000 litters.


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3 Stirred and jacketed fermentors/bioreactors (1000, 3000 and 3000 litters), for micro-organisms culture under anaerobic conditions for industrial production.

Including 1 Instrumentation and electronic panel with an HMI tactile Interface control system for stirring speed control and measurement and control of: process temperature, process pressure, media pH and media dissolved oxygen. SCADA software for process supervision, control and data acquisition from a PC with remote connection via TCP/IP protocol over ETHERNET LAN.

All the equipments are manufactured in stainless steel AISI 316L, in compliance with all the sanitary and hygienic standards for veterinary and pharmaceutical industry. They have vacuum resistance and all of them are “in situ” steam sterilizable.

comparable projects actual...

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