Membrane separation technology overcomes challenges in fermentation broth filtration, sterilization, and clarification

In recent years, membrane separation technology has been successfully applied in the clarification and purification, as well as concentration and refinement processes of fermentation broth, effectively resolving the challenges of separation and purification, and concentration in the industrial production of fermentation broth. At the same time, it has achieved clean production and energy-saving goals, providing economic, advanced, and reasonable solutions for fermentation broth producers.

Most fermentation broth sterilization and clarification processes employ traditional solid-liquid separation equipment such as plate and frame filters, vacuum drum filters, centrifuges, diatomite machines, or use methods like flocculation sedimentation, crystallization, and isoelectric point precipitation. These methods can only provide rough separation of solid materials like mycelia and solid impurities in the fermentation broth, but cannot separate the large amounts of soluble proteins, colloids, impurity polysaccharides, pigments, and suspended particles present. The filtrate has low light transmittance, resulting in low product purity. Additionally, these traditional processes have drawbacks such as numerous extraction steps, low product yield, significant water washing requirements, high labor intensity, large amounts of wastewater discharge, and difficulty in wastewater treatment.

Fermentation broth membrane concentration process flow.

Fermentation broth → Membrane filtration (clarification, recovery of biomass) → Membrane concentration (dehydration, desalination, removal of small molecular impurities) → Subsequent processes

Fermentation Liquid Membrane Separation and Concentration Technology

Microfiltration or ultrafiltration is employed for solid-liquid separation of fermentation broth to remove large molecular substances such as mycelium, proteins, viruses, and pyrogens, while small molecular metabolites (including target products), salts, and water pass through the microfiltration or ultrafiltration membrane. Secondary ultrafiltration of the permeate is performed when necessary. Ultrafiltration technology can enhance permeation to improve yield. Moreover, since the concentration of the target product in the ultrafiltered permeate is lower after filtration, it allows for savings in solvents and energy consumption in subsequent processes. This not only increases yield and product quality but also simplifies the process flow, reduces costs, and produces high-quality products.

Fermentation broth membrane concentration process advantages:

The process is conducted at room temperature, with mild conditions and no component damage, making it particularly suitable for heat-sensitive materials.

2. Pure physical filtration, without phase or quality change, does not damage active ingredients.

High filtration efficiency, uniform pore distribution, enabling effective purification and concentration of fermentation broth components.

4. The system operates simply, with a short process, easy to clean and maintain.

5. After fermentation broth is concentrated through a filter membrane, it offers smaller volume, faster loading time, and reduced resin consumption. Additionally, it enables the simultaneous recovery of mycelium, enhancing production efficiency and extending the lifespan and regeneration cycle of the resin.

6. System runs with error-free operation design, eliminating the need for filter aid addition and introducing new impurities, thus completely resolving the issue of pollution and blockages.

7. Modular system design with easy filter material replacement, featuring online regeneration and cleaning, as well as effluent discharge units, which reduces labor intensity and production costs while enhancing production efficiency.

8. Selected stainless steel sanitary materials meet QS quality standards.

9. Automated PLC control system reduces labor intensity, and the membrane filtration process is conducted in closed containers, achieving clean production.

Yuwan Membrane customizes a cost-effective process package based on the treatment requirements of fermentation broth concentration, conducting a comprehensive analysis and rational design of the entire system. This ensures effective control over the design, manufacturing, production, and monitoring of each process step, thereby combining the economic performance and technical advantages of the fermentation broth filtration process package. As a result, we provide clients with both professional and comprehensive process package designs.