Air compressor and fermentation process in the pharma industry

Last edited on 20.02.2023

Fermentation filtration for air and gas is a critical and complex process in the pharmaceutical industry to produce a wide range of pharmaceutical products. Normally there are two types of fermentation processes; aerobic and anaerobic fermentation.

Here’s an explanation of what is aerobic and anaerobic fermentation:

1. Anaerobic fermentation takes place in the absence of oxygen, and

2. Aerobic fermentation needs oxygen, supplied via blower and compressor systems, to yield micro-organisms and produce the desired product.

In this blog, our compressed air experts share the guidelines for right aeration equipment in fermentation process for reliable plant production.

An overlooked consideration in aeration systems is the choice of compressor system. The inefficient compressed air system can lead to many problems in the fermentation applications e.g.

• Pressure drop
• Flow 
• High compressor noise
• High maintenance time and cost
• Power losses

The compressor equipment should have the following features to meet fermentation process requirements.

Equipment reliability: We recommend having aeration equipment dedicated to the fermentation process and sized properly for process needs for both aerobic and anaerobic fermentation. It is highly recommended to have a class-0 certified compressor considering the criticality of the fermentation process. The class 0 oil-free compressor ensures 100% oil-free air for the application thus avoiding any contamination in the product. 

The rotary positive displacement machines are much better in terms of reliability, efficiency, and noise-free operation in the long run. For optimal process efficiency, you may use low-pressure compressors at a 1.0 bar(g) – 3.5 bar(g) pressure range.

Energy efficiency: Our experts recommend gear-driven, direct coupling is driven compressor units for energy efficiency. These compressor units avoid power loss against traditional belt transmissions. Single-stage equipment designed for the lower operating pressures of fermentation tanks can reduce operating costs. VFD or VSD equipment further improves this efficiency to accommodate variable oxygen demands at various stages of fermentation.

Controllability: Air compressors with an advanced microprocessor can help monitor the compressor's critical parameters. You can also view these parameters remotely for better control of the compressor and, thus, high up-time. With one of our innovative technology - SMARTLink, you can remotely monitor your compressors at all times, even from a mobile device. Smartlink gives full insights into compressor performance to make smarter and more informed decisions.

In summary, fermentation filtration for air and gas is a critical process for producing pharmaceuticals product. Hence, it is important that the right compressor equipment with a proper system layout & control scheme should be chosen for smooth, reliable plant production at the lowest possible operational cost.