Filtration Improvement in the Fermentation Process · polypropylene depth media filters to remove...
Transcript of Filtration Improvement in the Fermentation Process · polypropylene depth media filters to remove...
Filtration Improvement in theFermentation Process
With Enzyme manufacturing the fermentation process is a critical component to delivering a desired product that meets specification. However fermentation operations are continously being challenged with meeting precise process conditions, demands of higher volumes and decreasing costs while maintaining the integral products being produced. Contamination from competing microbes put process yields at-risk and as a result profits can quickly diminish. The purity of both process liquids and air is critical to the success of the company.
PROCESS CHALLENGES Enzyme manufacturing is a highly technical, complex and costly operation requiring attention to detail to ensure pure and quality products. With industrial grade enzyme manufacturing, the fermentation-based process requires a small volume of inoculum (bacteria) immersed in a controlled medium that supports abundant enzyme growth. Bacterium, like Aspergillus niger, are subjected to a carbohydrate based medium in specific and controlled conditions (i.e. pH, temperature, oxygen content and nutritional ingredients) that multiply enzyme production. Once populated, the enzyme is separated from the ‘dead cells’ and further purified through separation by both centrifugation and continuous filtration techniques. The operation is costly with high margins, leaving minimal room for process interruptions. Achieving a smooth process requires a sound maintenance budget and schedule.
Routine maintenance reduces process interruption and it is imperative the enzyme manufacturer’s equipment operates smoothly to protect product quality. Per regular maintenance schedules, filter housings are inspected for increased differential pressure caused by accumulated particulate retention. Filter housings and filters are also steam sterilized after each batch process to reduce contamination. Production batches can be valued at several hundred thousand dollars and the slightest negative alteration in process conditions, such as being subjected to microbial and/or foreign particulate can contaminate and compromise product quality potentially leading to a complete loss of product.
BENEFITS OF AN OPTIMUM FILTRATION/SEPARATION SYSTEM:
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Protect Process Equipment
Minimize System Downtime
Lower Operating and Maintenance Costs
Improve Product Quality and Consistency
THE SOLUTIONFor over 10 years, Global Filter has proven our committment to supplying high quality filtration products for enzyme manufacturers. Having a well established customer relationships with key enzyme manufacturers and they know they can count on Global Filter to deliver exemplary product with knowledgeable technical aptitude to help solve filration related process issues. Global Filter has also built these trusted relationships by providing minimal lead times and competitive price structure. With these high volume operations requiring both liquid and air filtration, Global Filter is able to supply more economical prefiltration solutions such as meltblown and pleated polypropylene depth media filters to remove larger particulate. In addition, for compressed air and tank venting filtration, Global Filter can use is portfolio of soltuions to provide high purity hydrophobic membrane elements in either polysulfone or PTFE.
Global Filter’s PTFE membranes are integrity tested and have been validated for both bacterial reduction above a log reduction value (LRV) of 7 and even more rigorous testing to achieve a completely validated filter cartridge that meets sterilization requirements. Sterilizing grade filters are proven to remove equal to or above an LRV of 7 and have been validated in accordance with HIMA and ASTM F838-05 guidelines. Global’s sterilizing grade filter was also aerosol challenged with a MS2 bacteriophage. Polyethersulfone membrane filters also used for final liquid filtration before enzymes are further purified downstream via ultra- and nanofiltration. Global Filter’s products are known for handling higher flow rates while maintaining low pressure drops. These characteristics helps reduce the enzyme manufacturer’s maintenance down times and operation costs due to less energy consumption. It is due to this rigorous testing, high quality construction and responsiveness that enzyme suppliers trusts Global Filter with their filtration needs, protecting their most valued process entity. Global Filter’s products meet these demands and other aggressive industrial environments where robust construction yet attention to fine detail matter.
The purity of both process liquids and air is critical to the overall success of the company.
Enzyme Manufacturing 04/18
With high volume operations requiring both liquid and air filtration Global Filter is able to supply more economical prefiltration solutions
Enzyme Manufacturing 04/18
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FILTER
NutrientTank
Fermentation Tank
DE TrapFilter
H2O
3
FILTER
2
FILTER
DE Filter
11
FILTER
Global PP or MBElements
Global PTFE or PSH Elements
Global PTFEor PSH Elements
GlobalPES
Elements
GlobalPP or FGElements
GlobalPP or FGElements
10
FILTER
5
FILTER
StorageTank
Prefilters
7
FILTER
GlobalPES
Elements
GlobalPP or FGElements
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FILTER
Gas Duct
Air 1FILTER
Global PTFE or PSH Elements
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FILTER
GlobalPES
Elements
GlobalPP or FGElements
8
FILTER
PrefiltersPrefilters
Drums for final product
MicrofiltrationUltrafiltration
GLOBAL FILTER SOLUTIONS FOR THE FERMENTATION PROCESS
This schematic should be viewed as a general example of where filtration systems could be located within a fermentation process. These processes will vary between companies and facilities. As such, each appli-cation should be reviewed and considered individually in order to choose the correct system technology.
Filter Solutions for Stages of the Fermentation Process
Location Global Filter Solutions Filter Purpose Filter Benefit
1. Inlet Air
PTFE Hydrophobic Membrane General Grade • GGPTFE, BRPTFE, PPTFE Series
PS Hydrophobic Membrane • Polysulfone - PSH Series
Removal of particulated such as sediment, suspended solids, pipe scale, etc. from process water
Maintains aeration efficiency for bacterial growth and production
2. Inlet H20
Polypropylene Meltblown • GWTB, GCTB, GATB Series
Pleated Polypropylene • PP, PPE Series
Removal of particulate and bateria from process air
Maintains water quality as an ingredient
3. - 4. Fermentation
Tank
PTFE Hydrophobic Membrane General Grade • GGPTFE, BRPTFE, PPTFE Series
PS Hydrophobic Membrane • Polysulfone - PSH Series
Fermentation tank vent filtration
Allows for bacteria free air passage during filling and evacutaiton, protecting the fermentation tank and its contents from contamination
5. DE Trap Filter
Pleated Microglass • FG, FGE Series
Pleated Polypropylene • PP, PPE Series
Installed downstream of the Diatomaceous Earth (DE) filter to prevent DE bleed-through fines from entering product
Maintains high quality of the process and minimized sediment and poor quality perception of the final product
6. - 11. Pre and Post
Filtration to Micro and Ultrafiltration
Pleated Microglass • FG, FGE Series
Pleated Polypropylene • PP, PPE Series
Pleated Polyethersulfone • GWPES, WCPES, GGPES, GFPES, GBPES, BRPES, PPES Series
Removal of coarse and fine particulate
Pre-filtration of finished product before micro and ultrafiltration