Small Scale Bioreactor - An Efficient Method of Cultivating Microorganisms on a Compact Scale

 

Small Scale Bioreactors 

Laboratory Bioreactors provide an efficient method for cultivating microorganisms on a compact scale suitable for research, development and small-scale production purposes. Compared to flask shaking cultures which are labour intensive and provide poor process control, bioreactors automate mixing, aeration and other parameters to create ideal growth conditions. This allows for consistent, scalable experimentation and manufacturing even with limited space and budgets.

Types of Small Scale Bioreactor

There are several types of Laboratory Small Scale Bioreactors suitable for different applications and throughput needs:

Benchtop Bioreactors

Benchtop systems are self-contained, compact units designed for cultivation volumes between 100ml to 5 liters. They connect directly to utilities and feature integrated controls and sensors for parameters like pH, dissolved oxygen, temperature and foam level. Automated mixing is provided by either axial or radial impellers located within sterile vessels. Benchtop systems are well-suited for process development, cell line development and scale down modeling.

Micro-Bioreactors

For high-throughput screening of cultivation conditions, micro-bioreactors containing miniaturized reactor vessels ranging from microliters to milliliters are used. They allow running hundreds of parallel experiments to optimize media composition, aeration levels, inoculum size and other variables. Micro-Bioreactors integrate with robotics for automated sampling and analysis, leading to significantly accelerated process development timelines.

Spin Filter Bioreactors

For the cultivation of slow-growing or adherent cell types, spin filter bioreactors provide an ideal environment. Cultivation takes place on a microporous membrane inserted in a spin filter tube that is continuously rotated. Nutrients are supplied from below while waste is removed from above, mimicking the laminar flow in commercial-scale bioreactors. Spin filter systems are well-suited for applications like monoclonal antibody production.

Key Components and Operation of Small Scale Bioreactor

Regardless of the type, all Laboratory Bioreactors share some key components that work together to automate the culturing process:

Vessel - The sterile, single-use vessel where cultivation takes place. Various sizes and configurations are available.

Impeller System - Composed of one or multiple impellers that create turbulent mixing through mechanical agitation, ensuring even distribution of nutrients, gases and cell suspension.

Dissolved Oxygen Control - Systems actively regulate the dissolved oxygen (DO) level through controllers that adjust agitation rate and gas flow/percentage to keep DO at the set-point.

pH Control - Buffers and acids/bases are automatically dosed to maintain optimal pH for cell growth.

Temperature Control - Jackets and heat exchangers circulate water or refrigerant to control media temperature.

Automated Software - Intuitive interfaces enable setup of cultivation parameters and profiles. Real-time data from integrated sensors is logged and can be analyzed post-run.

The microprocessor-controlled systems require minimal hands-on operation. Sterilized media is loaded along with inoculum and the run is initiated from the software. All parameters are maintained automatically as per the programmed profiles until the desired cell density, viability or stationary phase is reached.

Applications of Small Scale Bioreactor

Due to their flexibility, precise control capabilities and automated operation, Laboratory Bioreactors have enabled expanded application of cell culture technology in areas like:

Process Development

Detailed experimentation with varying parameters helps optimize processes for maximum productivity and quality early on.

Seed Trains

Reproducible scale-up from lab scale bioreactors aids qualification of inoculum for production bioreactors.

Production of High-Value Materials

Things like vaccines, gene-modified cell therapies require extensive development work before production - enabled by small scale systems.

Bioartificial Liver Support Devices

These rely on hepatocyte function maintained through repeated-batch cultures in bioreactors.

Microbial Fermentation

For secondary metabolites, organic acids etc. produced through fungal and bacterial culture.

Cell Line Development

Rapid screening and selection of high producing clones is facilitated by parallel micro-bioreactor platforms.

Toxicity Testing

Assessing drug/compound toxicity through culturing various cell types like hepatocytes, neurons in controlled conditions.

Advantages of Small Scale Bioreactor

Some key benefits of automated Laboratory Bioreactors over conventional flask cultures include:

- Superior process control and reproducibility through real-time monitoring and regulation of critical parameters.

- Higher cell densities and product titers achievable through optimized mass transfer capabilities.

- Less manual labor and hands-on time required due to integrated automation.

- Scale-down modeling from industrial to laboratory scale for robust process characterization.

- Parallel operation enables extensive experimentation and optimization in limited space.

- Facilitates faster product and process development at low-capital investment.

- Easy to use interfaces and intuitive software for experiment design and data analysis.

- Single-use consumables eliminate cross-contamination risks and clean-up times.

Small Scale Bioreactor provide efficient, predictable and scalable platforms well-suited to meet the evolving needs of cell culture applications in research, development, manufacturing and healthcare. Their benefits have led to growing utilization across diverse industries.

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About Author:

Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)