Fermentation Services

Regarding the use of fermentation engineering in the pharmaceutical sector, notable outcomes have been obtained, including the development of antibiotics, vitamins, animal hormones, therapeutic amino acids, nucleotides (such inosine), and more.

Fermentation is a bio-chemical reaction. Yeast cells participate on biological activity, while sugar (C12H22O11) is involved in the fermentation process used for the manufacturing of alcohol. Overall fermentation process is very complex. Fermentation is divided into following steps. In principle, glucose molecules are consumed by yeast cells and in turn they excrete ethanol molecules and liberate carbon dioxide. This is an exothermic reaction, Following equation represents the fermentation reaction: yeast C6H12O6 = 2 C2H5OH + 2 CO2 + Heat Living yeast cell generates an enzyme, called as invertase enzyme, at the cell wall surface. These enzymes hydrolyze one sugar molecule (disaccharide) into two mono-saccharide molecules, called as glucose and fructose. This mono-saccharide is involved in conversion to alcohol. Following equation represents the hydrolysis of sugar to glucose fructose at cell surface C12H22O11 + H2O = C6H12O6 + C6H12O6 (Disaccharides) Invertase Inzyme (Monosaccharide)

Microbial fermentation services leverage microorganisms to biomanufacture a wide range of products by using their metabolic processes to convert organic substrates into desirable compounds. Services include developing and optimizing fermentation processes for biologics, vaccines, antibodies, enzymes, and plasmids, and can also include the production of vitamins, amino acids, organic acids, and ingredients for food, beverages, and agriculture. These services support clients from pre-clinical development through commercial-scale manufacturing in various industries like pharmaceuticals, food, agriculture, and biofuels.

Our Fermentation Services offer advanced solutions for the controlled fermentation of food, beverages, and industrial products. We help businesses optimize production processes, enhance product quality, and ensure safety and consistency. Key Services Include: Microbial Fermentation: Cultivation of bacteria, yeast, and other microorganisms for dairy products, beverages, and probiotics. Process Optimization: Fine-tuning temperature, pH, and nutrient conditions to maximize yield and product consistency. Quality Monitoring: Regular testing of microbial activity, metabolite production, and contamination control. Product Development Support: Assistance in creating fermented products such as yogurt, kombucha, cheese, beer, and bioactive compounds. Analytical Safety Testing: Evaluation of acidity, alcohol content, flavor profile, and microbial safety. Scale-up Services: Transition from lab-scale fermentation to pilot or industrial-scale production efficiently.

High efficiency, rugged and reliable fermentation technologies are available under the brand name Hiferm to process different feed-stocks:

Production scale Fermentor used in pharma and biotech and agriculture industry for various bio pharma product manufacturing.We are manufacturing whole Fermentor plant as per customer requirement We are manufacturing Fermentor up to 100000Liter capacity.Fermentation Vessels manufactured by Maruti Engineering Works are the most flexible designed product to meet the requirements of the Pharmaceutical Industry.Technical SpecificationsFilling Volume 65-80% Material Wetted parts are SS316L, and others is SS304 Surface Finish inside surface is Matt finish AgitationFermentor use SEW / Bonfigloli decelerator top mechanical agitator with two layer six blade impeller, one layer defoamer and four baffles. mechanical seal (single or double mechanical seal) speed range 50-400rpm (it depends on the size of the vessel) Or Top mounted agitator with speed variation from 20 to 500 RPMEquips of vesselusing alcohol flame inoculation sterilisable sampling and Flush bottom valve CIP SIP system inbuilt. PH, DO, temp. sensor on lower side, side glass, top with foam and level probe.Construction Floor-type One fermentor vessel with one control systemCapacity5 0L to 30000LMax Temperature (degree celcius)200 Our vast experience helps us engage in the manufacture of quality SS Bend. They are made at our modern infrastructure facility using optimum quality raw-materials and are available to clients in multiple specifications at highly affordable market prices. They are highly demanded by various industries due to their superior functionality and efficiency. They are resistant to corrosion and moisture. They have high tensile strength as well. Their surface is sturdy and tough yet has a flawless finish. Various dimensions of these stainless steel bends are used for industrial applications. They are offered to clients within the specified time-frame at affordable costs. We also undertake bulk delivery of these products. Repair and maintenance services are provided for them.The Saturated Steam Autoclave is flexibly designed to meet the requirements of pharmaceutical industry. Available in standard and customized models, it is used in various research development and production applications. Features The equipment is low on operating cost and fast with autoclaving cycle and possess dimple steam jacket for uniform heat distribution.Available in single as well as double door with sliding or hinged door option.Touch screen is present to measure connection signals, printers and process control visuals.Sterile air filter is available for vacuum break.An optional SIP filter is also provided as per the requirements.To prevent the cross-flow of air between the clean and unclean area, a contamination seal is provided.To insert the temperature sensors, which support thermometric testing, validation ports are provided. Main Applications Empty glass labwareStoppersInox equipmentInox machine partsEmpty containersFilters and accessoriesRubber materialsTextilesLiquid solutions and culture media in sealed or unsealed containers (e.g. vials, bottles, ampoules)Plastic materials (able to withstand usual temperatures for saturated steam sterilization)

Fermentation is the oxidation process for both the CTC and Orthodox 'maal' and lasts between 100 to 180 minutes, depending on the colour and smell (nose) of the fermented leaf and also which initial process has been used. It is at this point that, when making black tea varieties, the green 'maal' turns a coppery red colour. Our factories use various types of fermentation processes such as 'Gumlah' fermentation and Continuous Fermentation Machines, whilst in Africa, larger fermentation trollies are used, but the same process is carried just in larger volumes.

With over 25 years of core expertise in Fermentation, our fermentation and process development services enable the customers in scaling up their process and product, from small scale development to industrial scale production. Microbiological Experience E. coli, Pichia, Bacillus sp. Experience - Enzymes - Secondary metabolites - Biomass - Biotransformation approaches

In 1999, we commissioned our first large scale submerged (or stirred-tank) fermenters capable of handling bacteria, yeast, fungal and actinomycete cultures. This capacity was further expanded in 2006 on our second site, Biocon Park, to cater to the anticipated additional demand for several small molecule generics such as the statins, anti-obesity products and pharmaceutical enzymes. Our multi-product submerged fermentation facility comprises production fermenters ranging in size from 30,000L to 125,000L and several seed fermenters, nutrient dosing vessels and media batching tanks. Operations are fully automated to control key process parameters such as temperature, pH, dissolved oxygen and nutrient dosing using sophisticated DCS control. The fermentation and associated downstream suites are dedicated depending on the nature of product. The products mainly fall into three categories: Insulin and AnalogsImmunosuppressantsStatinsAt the end of the fermentation process, the broth is harvested and processed in different downstream facilities depending on the nature of the product. Purification of Insulin and analogs involves cell harvest followed by several chromatography and crystallization steps and bulk lyophilization. The downstream suite for purification of Insulin is a highly controlled area with supply of HEPA filtered air and utilities like Purified water, pure steam and Water for Injection. The process areas are controlled through Building Management System (BMS)

Wort, yeast and sterile air are mixed uniformly in the unitank for generation of alcohol by fermentation. Apart from quality of such ingredients, the most important factors is the design aspect of the Fermenters vessels and its accessories. Well-designed Fermenters deliver freedom of yeast growth and multiplication. Most brewers are concerned for the stuck fermentation. Temperature, pH and concentration are controlling parameters for smooth fermentation. IDMC's Fermenter vessel is characterized by specially designed fast chilling jackets for varying duties. The tank top fittings and the bunging devices of IDMC are designed carefully to maintain robust operation. The unitank are designed as per ASME standards.

Microbial Fermentation Service

Fermentation Services

Fermentation Services

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FERMENTATION FACILITY

Precision Fermentation

Precision Fermentation Services