Brewing technology for the fermentative production of alternative proteins

Using precision fermentation, animal or plant cells can be specifically programmed or optimised to produce a specific product such as enzymes, fats, proteins, vitamins, flavourings and natural pigments. Fermentatively produced proteins can then be combined with other ingredients and further processed to reproduce meat, egg or dairy products.

A concrete example of the cultivation and replication of such proteins is biomass production. Here, cells are placed in a tank where cell multiplication is initiated. And this is exactly where Steinecker comes into play with its own bioreactor. The key factor: It was developed on the basis of the proven Poseidon fermentation unit from brewing technology and works with a circulation unit instead of an agitator. In addition, the recirculation unit is equipped with aseptic valve technology from Evoguard and a low-shear aseptic pump. Integrated in a sterile tank with steam or condensate barrier, cells can be cultivated or fermentations carried out.

Brochure Bioreactor by Steinecker

0.59 MB, .pdf

Tasks of a bioreactor

Homogenization	to prevent sedimentation of cells
Mixing	to provide adequate mass transfer of nutrients within the overall tank volume to provide adequate heat transfer between the tempering jacket and the tank contents
Aeration	to supply the cells with oxygen
Feeding	to supply the cells with nutrients and other ingredients
Sampling
Sterile environment	to prevent contamination

The recirculation of the tank volume under sterile conditions is the key task of an efficient fermentation process.

Method of operation of the dynamic fermentation

Recirculation for an efficient fermentation

Various outlet housings at different heights within the tank: are not only used as outlet but also as inlet
Continuous mixing in a recirculation circuit: use of a recirculation unit instead of an agitator
Representative measurements of process parameters by means of continuous flow through the field devices in the circuit
Less spray shadow during cleaning
Maintainability through easy accessibility of seals, field devices and motors
Possibility of a fed-batch process by recirculation with the top opening
Can be retrofitted into existing tanks
Different flow directions possible (for homogenization, aeration, fluidized bed process or sedimentation for cell harvesting)
Flexibility through pipe diameter dimensioning and adjustment of the volume flows in the pipe system

Tank construction – From tank to bioreactor

Our expertise

Manufacturing halls specially designed for tank construction
Automated processes for tank dome and shell production
Precisely coordinated work steps, carried out by qualified welders
High-performance and program-controlled production machines for cutting, drawing and welding work
Highest quality through a globally recognised and standardised welding and inspection procedure
Surface treatment with polishing and pickling solutions, including ceramic blasting of the outer surfaces

The benefits of the Steinecker bioreactor

Efficient solution for high production outputs

The use of a recirculation unit enables the realisation of high production volumes, and the costs still remain within reasonable limits.

Use of approved technology

As the bioreactor is based on the concept of the Steinecker Poseidon, it is based on a tried-and-tested technology that has already proved successful in practice at numerous breweries.

Many years of experience in plant engineering

As expert in brewing technology, Steinecker can look back on almost 150 years of experience in plant engineering. Customers who want to open up completely new markets in the area of vegan food alternatives are now also benefiting from this knowledge and are utilising Steinecker's proven technology to do so.