Customized Reactor
Precision-engineered glass reactor systems designed for both industrial wastewater treatment research and life science cell culture applications. Our customizable bioreactors feature advanced process control, sterile operation capabilities, and modular configurations to support everything from laboratory-scale experiments to pilot-scale environmental studies and biopharmaceutical production.
Industrial-Grade Bioreactors for Wastewater Applications
Wastewater Treatment Bioreactor Systems
Simulate and optimize biological treatment processes:
- Bench-Scale Reactors (1L - 5L) - Laboratory kinetic studies | Microbial consortium development | Treatment optimization | Footprint: 40cm × 40cm | Ideal for university research and method development
- Pilot-Scale Reactors (10L - 50L) - Semi-industrial testing | Process scale-up validation | Industrial effluent treatability studies | Footprint: 80cm × 80cm | Bridging lab to full-scale implementation
- Industrial Demonstration Units (100L - 500L) - On-site pilot studies | Full-scale process simulation | Regulatory compliance demonstration | Custom footprint | Designed for field deployment at treatment facilities
Wastewater Bioreactor Configurations
Multiple reactor types for diverse treatment scenarios:
- Activated Sludge Reactors - Conventional aerobic treatment simulation | Adjustable hydraulic retention time (HRT) and sludge retention time (SRT) | Integrated aeration control | Real-time dissolved oxygen monitoring | Applications: municipal wastewater, industrial BOD/COD reduction
- Sequential Batch Reactors (SBR) - Programmable fill-react-settle-decant cycles | Automated timing control | Nutrient removal (nitrogen and phosphorus) | Space-efficient design | Applications: small communities, industrial batch discharges
- Membrane Bioreactors (MBR) - Integrated membrane filtration | High-quality effluent | Compact footprint | Fouling characterization studies | Applications: water reuse, high-strength industrial wastewater
- Anaerobic Digesters - Gas-tight construction | Biogas production and measurement | Temperature control for mesophilic (35°C) or thermophilic (55°C) operation | pH and redox monitoring | Applications: sludge digestion, high-COD wastewater, biogas generation
- Moving Bed Biofilm Reactors (MBBR) - Suspended carrier media | High biomass concentration | Compact design | Biofilm development monitoring | Applications: nitrification, denitrification, carbon removal
- Anoxic-Oxic (A/O) Systems - Multi-chamber configuration | Sequential anoxic and aerobic zones | Nutrient removal optimization | Recirculation control | Applications: nitrogen removal, phosphorus removal
Wastewater Treatment Applications
Research and process development for diverse industries:
- Municipal Wastewater Treatment - BOD/COD removal optimization | Nitrification/denitrification kinetics | Phosphorus removal studies | Seasonal variation simulation | Temperature effect on treatment efficiency
- Industrial Effluent Treatment - Pharmaceutical manufacturing wastewater | Food and beverage processing | Chemical manufacturing | Textile dyeing effluent | Pulp and paper industry | High-strength organic wastewater
- Agricultural Wastewater - Dairy processing effluent | Livestock waste treatment | Aquaculture discharge | Nutrient-rich runoff | Seasonal loading variations
- Specialized Applications - Antibiotic resistance gene (ARG) fate during treatment | Micropollutant removal (pharmaceuticals, personal care products) | Pathogen inactivation studies | Disinfection byproduct formation | Heavy metal biosorption
- Resource Recovery - Biogas production from organic waste | Nutrient recovery (ammonia, phosphate) | Biosolids valorization | Energy-positive wastewater treatment
Life Science Cell Culture Bioreactors
Mammalian Cell Culture Systems
Sterile bioreactors for biopharmaceutical applications:
- Small-Scale Culture (500mL - 2L) - Process development and optimization | Cell line screening | Seed culture preparation | Compact benchtop footprint | Single-use or reusable glass vessels
- Laboratory Production (5L - 20L) - Protein production for research | Antibody development | Vaccine production studies | Adequate yield for downstream purification | GMP-ready design available
- Pilot-Scale Production (50L - 200L) - Clinical trial material production | Process validation | Scale-up studies | FDA/EMA regulatory compliance | Full documentation package
Microbial Fermentation Systems
High-density bacterial and yeast cultivation:
- Bacterial Fermentation - E. coli, B. subtilis, P. pastoris production | High oxygen transfer rate capability | Foam control systems | Fed-batch and continuous operation | Recombinant protein expression | Enzyme production | Metabolite synthesis
- Yeast Fermentation - S. cerevisiae, P. pastoris cultivation | Ethanol production studies | Biofuel research | Industrial enzyme production | Temperature-controlled fermentation | pH-stat feeding control
- Fungal Cultivation - Filamentous fungi growth | Secondary metabolite production | Antibiotic biosynthesis | Complex morphology handling | Customized impeller designs
Specialized Cell Culture Applications
Advanced bioreactor configurations for specialized needs:
- CHO Cell Culture - Chinese Hamster Ovary cell production | Monoclonal antibody manufacturing | Perfusion culture mode | High-density culture (>20 million cells/mL) | Biopharmaceutical industry standard
- Hybridoma Culture - Antibody-producing cell lines | Batch and fed-batch modes | Serum-free media optimization | Monoclonal antibody production | Diagnostic reagent manufacturing
- Insect Cell Culture - Sf9, Sf21, High Five cells | Baculovirus expression system | Recombinant protein production | Vaccine development | Lower temperature requirements (27-28°C)
- Stem Cell Culture - Mesenchymal stem cells (MSC) | Induced pluripotent stem cells (iPSC) | 3D culture systems | Bioreactor-based expansion | Regenerative medicine applications
- Algae Cultivation - Photobioreactor configurations | Light control systems | CO2 supplementation | Biofuel production | High-value compound extraction | Carbon capture research
Reactor Features & Process Control
Advanced Temperature Control
Precision thermal management for optimal growth conditions:
- Jacketed Vessel Design - Double or triple-wall glass construction | Circulating water/oil for heating and cooling | Temperature range: 4°C to 180°C | Accuracy: ±0.1°C with PID control
- Heating/Cooling Systems - Integrated electric heaters for small reactors | External circulation baths for large systems | Cryogenic cooling for low-temperature applications | Automated temperature ramping
- Applications-Specific Settings - Mammalian cells: 37°C ±0.5°C | E. coli fermentation: 30-37°C | Thermophilic bacteria: 55-65°C | Psychrophilic organisms: 4-15°C
pH Control & Monitoring
Automated pH regulation for stable culture conditions:
- Dual Probe System - Primary pH electrode with automatic compensation | Backup redundant sensor | Hot-sterilizable probes (121°C) | Long-term stability (±0.02 pH units)
- Automated Titration - Peristaltic pump dosing of acid/base | Programmable pH set-points (pH 3-11) | Dead-band control to minimize oscillation | Separate acid and base reservoirs
- Applications - Maintain optimal pH for cell growth | Compensate for metabolic acid production | Fed-batch pH-stat feeding strategies | Lactate accumulation control
Dissolved Oxygen (DO) Control
Critical oxygen delivery for aerobic processes:
- DO Measurement - Optical or polarographic sensors | Real-time monitoring (0-200% saturation) | Autoclavable probes | Minimal drift during long cultivations
- Cascade Control Strategy - Stage 1: Agitation speed control (300-1500 RPM) | Stage 2: Gas flow rate adjustment | Stage 3: Oxygen enrichment (air/O2 blending) | Maintains set-point while minimizing shear stress
- Mass Transfer Optimization - Various impeller designs (Rushton, pitched blade, marine) | Sparger configurations (ring, sintered, frit) | kLa determination studies | Oxygen uptake rate (OUR) calculations
Agitation & Mixing Systems
Optimized mixing for diverse applications:
- Variable Speed Drive - Digital motor control (10-1500 RPM) | Low-shear for mammalian cells (50-150 RPM) | High-shear for bacterial fermentation (500-1200 RPM) | Programmable speed profiles
- Impeller Options - Marine impeller (low shear, mammalian cells) | Rushton turbine (high oxygen transfer, bacteria) | Pitched blade (general purpose) | Custom designs for viscous broths or mycelial cultures
- Magnetic Coupling - Hermetically sealed drive system | No shaft seal = sterility maintained | Prevents contamination ingress | Suitable for long-term (>30 days) cultivations
Aeration & Gas Control
Precise gas delivery for optimal growth:
- Mass Flow Controllers - Independent control of air, O2, N2, CO2 | Flow range: 0.01-10 L/min (LPM) | Digital set-points and real-time display | Blend gases for optimal growth conditions
- Gas Sterilization - 0.2μm hydrophobic filters on inlet and exhaust | Autoclavable filter housings | Prevents airborne contamination | Maintains sterility for weeks
- Exhaust Gas Analysis - Optional O2 and CO2 sensors on outlet | Respiratory quotient (RQ) calculation | Oxygen uptake rate (OUR) determination | Carbon dioxide evolution rate (CER) | Metabolic state monitoring
Sterility & Contamination Control
In-Situ Sterilization (SIP)
Integrated steam sterilization for glass and stainless steel components. 121°C, 20 minutes cycle. Automatic validation with temperature probes. F0 value calculation and documentation. Eliminates need for autoclave for large reactors.
Single-Use Technology (SUT)
Disposable bioreactor bags for mammalian cell culture. Pre-sterilized by gamma irradiation. No cleaning validation required. Rapid turnaround between batches. Ideal for multi-product facilities. Sizes: 2L to 2000L available.
Sampling Systems
Aseptic sampling ports for sterile sample collection. Steam-sterilizable sample valves. Syringe-based or automated sampling. Septum ports for inoculation. Minimal contamination risk. Maintains culture sterility throughout run.
CIP/SIP Capability
Clean-in-place (CIP) systems with spray balls. Automated cleaning cycles. Validated cleaning procedures. Steam-in-place (SIP) for terminal sterilization. Meets pharmaceutical GMP requirements. Full documentation for regulatory compliance.
Data Acquisition & Process Control
Real-Time Monitoring
Touchscreen HMI (Human-Machine Interface) displays all parameters. Data logging at user-defined intervals (1-60 seconds). Trend graphs for pH, DO, temperature, RPM, gas flows. Alarm limits with visual and audible warnings.
Recipe Management
Store up to 100 process recipes. One-touch recipe recall. Set-point changes during run. Fed-batch feeding profiles. pH-stat and DO-stat modes. Time-based or sensor-triggered additions.
Data Export & Compliance
Export data to CSV, Excel formats. USB data backup. Network connectivity for LIMS integration. FDA 21 CFR Part 11 compliant options. Electronic signatures and audit trails. Suitable for GMP facilities.
Remote Access
Web-based interface for remote monitoring. Mobile app for iOS and Android. Email/SMS alarm notifications. Off-site process supervision. Multi-reactor dashboard view. Secure encrypted connections.
Why Choose Our Customized Reactors?
Modular & Expandable
Start with basic configuration and add sensors/controllers as needed. Upgrade analog to digital control systems. Add advanced features without replacing entire reactor. Protect your investment with scalable design.
Application Flexibility
Same reactor platform for wastewater and cell culture (with sterilization). Quick changeover between projects. Multi-purpose laboratory equipment. Maximize utilization and ROI.
Regulatory Support
Design qualification (DQ) documentation. Installation qualification (IQ) protocols. Operational qualification (OQ) testing. Performance qualification (PQ) assistance. Suitable for FDA, EMA, ICH inspections.
Expert Consultation
Free reactor design consultation with our bioprocess engineers. Application-specific recommendations (wastewater vs. cell culture). Impeller and sparger selection guidance. Process optimization support.
Quality Construction
Borosilicate 3.3 glass vessels (chemical resistant, autoclavable). 316L stainless steel metalwork (corrosion resistant). CE-marked electrical components. 2-year warranty on reactor system. 5-year warranty on glass vessel.
Comprehensive Training
On-site installation and commissioning. 2-3 day operator training included. Standard Operating Procedure (SOP) templates. Troubleshooting guide. Annual refresher courses available.
Custom Reactor Design Process
Step 1: Application Consultation - Describe your process (wastewater treatment or cell culture). Specify target organisms and culture conditions. Define required working volume and throughput. Discuss regulatory requirements (if applicable).
Step 2: Requirement Analysis - Our engineers assess critical process parameters. Recommend reactor type and configuration. Identify required sensors and control loops. Propose vessel size and geometry.
Step 3: Detailed Design - CAD drawings with dimensions and specifications. Piping and instrumentation diagram (P&ID). Control panel layout and wiring schematics. Bill of materials with part numbers.
Step 4: Manufacturing - 6-8 week fabrication for standard configurations. 10-12 weeks for highly customized systems. Quality inspections at each stage. Factory acceptance testing (FAT) before shipment.
Step 5: Installation & Validation - On-site installation by certified technicians. System commissioning and leak testing. IQ/OQ protocol execution. Operator training and documentation handover.
Request a Custom Reactor Quotation
Every research group and industrial facility has unique requirements. Contact our bioprocess engineering team to discuss your application in detail. We'll design a reactor system optimized for your specific process—whether it's treating industrial wastewater, producing monoclonal antibodies, or cultivating novel microbial strains. Provide us with your process parameters and we'll deliver a comprehensive proposal within one week, including technical drawings, equipment specifications, and projected timelines.