Pollution-free sampling fermentation tank

Abstract

The utility model relates to a kind of pollution-free sampling fermentation tank, comprising: fermentation tank body, the fermentation tank body is formed into cylindrical tube and is equipped with fermentation chamber through along its axial direction direction inside;Sampling chamber, the sampling chamber is formed into cylindrical cavity, at least a part of the sampling chamber is located in the fermentation chamber and is communicated with the fermentation chamber, and the both ends of the sampling chamber are equipped with sampling valve group, and the material in the fermentation chamber is sampled and detected by the opening and closing of the sampling valve group.The core structure of the application limits the fermentation tank body to combine built-in sampling chamber and sampling valve group, and constructs the basic framework of pollution-free sampling.The opening and closing of sampling valve group realizes the dynamic isolation of sampling process, and only material flow is controlled by valve group during sampling, to avoid the volume residual problem of traditional external pipeline.

Description

Technical Field

[0001] This utility model relates to the field of fermenters, and in particular to a pollution-free sampling fermenter. Background Technology

[0002] As core equipment in fields such as bioengineering, pharmaceuticals, and food, the fermentation tank's internal sterile environment directly affects product quality and production efficiency. During fermentation, it is necessary to monitor key parameters such as pH value, dissolved oxygen level, and cell concentration of the material in real time through sampling and testing. Therefore, the design of the sampling device must simultaneously meet the dual requirements of sterility and ease of operation.

[0003] In existing technologies, fermenter sampling methods mainly fall into two categories: one is an external sampling pipeline system, which connects to a sampling valve via a pipe extending into the tank. During sampling, the valve is opened to allow material to flow into the sampling container. This type of structure suffers from dead volume residue issues, and culture medium residue easily adheres to the inner wall of the pipe, forming a biofilm that leads to cross-contamination during subsequent sampling. The other type is open-top sampling, which requires pausing the fermentation process and opening the top or side cover of the tank to directly extract the sample. While this method can obtain representative samples, it disrupts the sealed environment inside the tank, allowing outside air and operator contact to introduce contaminants. Furthermore, frequent opening of the cover causes fluctuations in temperature and pressure inside the tank, affecting fermentation stability. Utility Model Content

[0004] To address the aforementioned technical problems, this application provides a pollution-free sampling fermenter.

[0005] The pollution-free sampling fermenter provided in this application adopts the following technical solution: A pollution-free sampling fermentation tank, characterized in that it comprises: The fermenter body is formed as a cylindrical tube and has a fermentation chamber that runs through it along its axial direction. The sampling chamber is formed as a cylindrical cavity. At least a portion of the sampling chamber is located inside and connected to the fermentation chamber. Sampling valve groups are provided at both ends of the sampling chamber. By opening and closing the sampling valve groups, the material in the fermentation chamber is sampled and tested.

[0006] Through the above technical solution, this application defines a basic framework for pollution-free sampling by combining the fermenter body with a core structure consisting of a built-in sampling chamber and a sampling valve assembly. Firstly, the sampling chamber, located within the fermentation chamber, shortens the sampling path and reduces the contact area between the external environment and the fermentation system, thus lowering the risk of contamination from a spatial layout perspective. Secondly, the opening and closing of the sampling valve assembly achieves dynamic isolation during the sampling process; material flow is controlled solely by the valve assembly during sampling, avoiding the dead volume residue problem of traditional external pipelines. Finally, the cylindrical sampling chamber is directly connected to the fermentation chamber, ensuring smooth material flow and stronger sample representativeness during sampling. This structure overcomes the design limitations of traditional external sampling pipelines, providing an integrated carrier for subsequent sterilization, filtration, and other functional modules through the combination of built-in design and valve assembly control, laying the structural foundation for overall aseptic sampling.

[0007] Furthermore, the sampling chamber is arranged laterally on the fermenter body, and the angle between the axial direction of the fermenter body and the setting direction of the sampling chamber is 40-50°.

[0008] Through the above technical solution, this application optimizes the spatial arrangement of the sampling chamber and the fermenter body by optimizing the angle design. The tilt angle creates a natural slope inside the sampling chamber, allowing the material to be discharged by gravity, avoiding bottom residue caused by traditional vertical or horizontal settings, and reducing the risk of biofilm contamination caused by culture medium residue. Secondly, the sampling chamber inlet forms a reasonable angle with the main fluid direction inside the fermenter, which can capture the dynamic mixing state of the material inside the tank during sampling, avoiding sample deviation caused by sampling in static areas.

[0009] Furthermore, the sampling chamber includes: A sampling port is located at the end of the sampling chamber away from the fermenter body; An internal valve is located at one end of the sampling chamber that extends into the fermentation chamber. An external valve is located at one end of the sampling chamber near the sampling port, and the inner valve and the external valve form a sampling cavity.

[0010] Through the above technical solution, this application constructs a double isolation barrier through a three-section structure of inner valve + outer valve + sampling chamber. The inner valve extends into the fermentation chamber, directly blocking the connection between the fermenter and the sampling chamber. Closing the inner valve before sampling prevents the aseptic environment inside the tank from being affected by external operations. The outer valve is close to the sampling port, forming a second layer of isolation. During sampling, only the outer valve needs to be opened to extract the sample, avoiding the problem of residual material backflow after sampling in traditional single-valve structures. The sampling chamber between the inner and outer valves forms an independent buffer space, which can be used for targeted sterilization before and after sampling, ensuring a sterile state throughout the sampling process. This structure decomposes the sampling process into three stages: isolation, sampling, and re-isolation. The orderly opening and closing of the valves achieves physical isolation between the operation and the aseptic environment.

[0011] Furthermore, the sampling chamber also includes a steam sterilization device, which comprises: A steam sterilization sleeve is fitted over the outer periphery of the sampling chamber to heat the sampling chamber. A coil is nested along the axial direction of the steam sterilization sleeve on the outer circumferential surface of the steam sterilization sleeve. The inlet and outlet of the coil are both located at the end of the steam sterilization device near the outer valve.

[0012] Through the above technical solution, this application achieves highly efficient sterilization of the sampling chamber through a steam sterilization sleeve combination design. The steam sterilization sleeve is fitted around the outer circumference of the sampling chamber, forming a ring-shaped heating space, which can heat the sampling chamber 360° without dead angles, overcoming the limitation of traditional external disinfection that only acts on the surface; secondly, the coil is nested along the axial direction, extending the residence time of steam in the sleeve, ensuring that heat is evenly transferred to the inner wall of the sampling chamber, and improving the thoroughness of sterilization; finally, the inlet and outlet of the coil are both located at the end near the external valve, so that steam enters from the side of the sampling chamber away from the fermenter, and condensate is discharged from the same end, avoiding condensate backflow towards the fermenter and reducing the risk of secondary contamination.

[0013] Furthermore, a replaceable filter assembly is provided between the external valve and the sampling port, and the filter assembly is detachably connected to the sampling chamber via a clamp-type quick-release structure.

[0014] Through the above technical solution, this application optimizes the filtration and maintenance performance during the sampling process. Filtering the material before sampling removes solid particles or impurities, preventing clogging of the sampling port or affecting detection accuracy. The replaceable design allows for flexible selection of filter types based on the characteristics of the fermentation broth, adapting to different fermentation scenarios. The clamp-type quick-installation structure enables tool-free filter removal, allowing operators to quickly replace filters without interrupting the fermentation process, reducing downtime and maintenance costs. Furthermore, the sampling chamber is formed of stainless steel metal, and the sampling chamber is connected to the fermenter body by flange sealing welding.

[0015] Through the above technical solutions, the stainless steel material used in this application has excellent corrosion resistance and biocompatibility, avoiding the leaching of metal ions and contamination of the fermentation liquid, and meeting the hygiene standards of pharmaceutical, food and other fields; the flange sealing welding ensures the connection strength between the sampling chamber and the fermentation tank body, prevents the risk of leakage under high pressure fermentation environment, ensures the stability of the sampling device under long-term high temperature and high pressure fermentation conditions, and extends the service life of the equipment.

[0016] Furthermore, the internal valve is a pneumatic diaphragm valve, which is remotely controlled to open and close via a PLC control system.

[0017] Through the above technical solution, this application improves the automation and accuracy of sampling operations by using the internal valve design of a pneumatic diaphragm valve. The diaphragm of the pneumatic diaphragm valve is in direct contact with the material, and there are no mechanical transmission parts inside the valve body, avoiding the contamination risk of traditional valves. The diaphragm valve is remotely controlled by a PLC, allowing operators to open and close the valve outside a sterile environment, reducing the risk of contamination caused by manual intervention. At the same time, it supports linkage with the fermentation control system to achieve timed and quantitative sampling.

[0018] Furthermore, the external valve is a manual shut-off valve, and a silicone sealing ring is provided inside the external valve.

[0019] Through the above technical solution, the manual shut-off valve adopted in this application has a simple structure, and the operator can flexibly control the opening degree according to the sampling requirements to adapt to the sampling speed of materials with different viscosities. Secondly, the silicone sealing ring has excellent elasticity and high temperature resistance, and can form a tight seal when the valve is closed to prevent external air or pollutants from entering through the sampling port. The two work together to improve the reliability and adaptability of the sampling process.

[0020] In summary, this application includes at least one of the following beneficial technical effects: 1. This application constructs a multi-layered aseptic protection system through the synergistic design of dual-valve isolation and a steam sterilization sleeve. The inner valve directly blocks the connection between the fermenter and the sampling chamber, while the outer valve forms a second physical barrier. This dual isolation effectively prevents reverse contamination of the fermentation system by the external environment during sampling. The steam sterilization sleeve provides 360° heating to the sampling chamber without dead angles, and the axial steam flow design of the coil ensures thorough sterilization, solving the problems of incomplete sterilization and microbial growth in residual materials in traditional sampling devices. This structure keeps the entire sampling process in a controllable aseptic environment, significantly reducing the risk of contamination by other microorganisms. It is particularly suitable for high-cleanliness requirements in biopharmaceutical and vaccine production scenarios, ensuring the accuracy of sample test results and the safety of fermentation products.

[0021] 2. This application simplifies sampling operations and maintenance processes through modular design. The replaceable filter assembly adopts a clamp-type quick-installation structure, allowing for rapid disassembly and replacement without tools. It adapts to different fermentation broth characteristics, avoiding the downtime and cleaning problems caused by clogging of traditional fixed filters. The internal valve is a PLC-controlled pneumatic diaphragm valve, while the external valve is a manual shut-off valve, forming an automatic + manual dual control mode. This supports automated sampling to reduce manual intervention while retaining the flexibility for emergency manual operation. The inclined design of the sampling chamber promotes natural material drainage, reducing residual cleaning steps. The overall structure integrates sampling, sterilization, and filtration functions into one unit, simplifying operation steps, shortening maintenance time, and improving the continuity and efficiency of fermentation production.

[0022] 3. This application enhances the adaptability and durability of the equipment through material selection and structural optimization. The sampling chamber utilizes stainless steel metal parts and flange sealing welding, offering strong corrosion resistance and eliminating connection gaps to avoid material residue and leakage risks, meeting GMP hygiene standards. The sampling chamber is at a 40-50° angle to the fermenter axis, minimizing interference with the flow field inside the tank while ensuring sample representativeness. The material combination of the inner valve diaphragm and the outer valve silicone sealing ring is suitable for high-temperature sterilization and long-term sealing requirements. This structure can integrate online detection sensor interfaces, supporting intelligent upgrades and adapting to the diverse process monitoring needs of modern fermentation production. Stable operation is maintained regardless of high-viscosity fermentation broth, high-pressure fermentation environment, or frequent sampling conditions, extending the equipment's service life. Attached Figure Description

[0023] Figure 1 This is a three-dimensional structural diagram of the pollution-free sampling fermenter in the embodiments of this application.

[0024] Figure 2 This is a cross-sectional view of the pollution-free sampling fermenter in the embodiments of this application.

[0025] Explanation of reference numerals in the attached drawings: 1. Fermentation tank body; 2. Sampling chamber; 21. Sampling port; 211. Filter assembly; 22. Inner valve; 23. Outer valve; 24. Steam sterilization device; 241. Steam sterilization sleeve; 242. Coil. Detailed Implementation

[0026] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0027] This application discloses a pollution-free sampling fermenter.

[0028] Reference Figure 1-2 The pollution-free sampling fermenter includes a fermenter body 1, which is formed as a cylindrical tube. The internal space, extending axially, is a fermentation chamber used to contain the fermentation material. The fermenter body 1 is welded from stainless steel, and its side wall has pre-set mounting holes through which the sampling chamber 2 is laterally embedded into the fermenter body 1. The sampling chamber 2 is also a cylindrical cavity, with its axis forming a 40-50° angle with the axis of the fermenter body 1. The inclined arrangement of the sampling chamber 2 ensures that its inlet is close to the center of the fermentation chamber, and its outlet extends to the outside of the fermenter body 1, forming a sampling port 21. The connection between the sampling chamber 2 and the fermenter body 1 is sealed by flange welding. The flange sealing surface uses a tongue and groove structure, combined with a high-temperature resistant silicone gasket, to ensure the airtightness of the fermentation chamber.

[0029] The sampling valve assembly includes an inner valve 22 and an outer valve 23, both positioned at opposite ends of the sampling chamber 2 along its axial direction. The inner valve 22 is a sanitary pneumatic diaphragm valve, with its body extending into the fermentation chamber. The valve stem is connected to the inner wall of the sampling chamber 2 via a sealing sleeve. The valve's control end is connected to a PLC control system via an air pipe for remote electric opening and closing. The outer valve 23 is a manual shut-off valve, located at the end of the sampling chamber 2 near the sampling port 21. Its body is threaded into the sampling chamber 2, and the valve seat has a built-in silicone sealing ring. Rotating the handwheel adjusts the valve opening, enabling manual control of the sampling flow rate. The space between the inner valve 22 and the outer valve 23 forms a sampling chamber. The inner diameter of this chamber is identical to that of the sampling chamber 2, ensuring seamless material flow.

[0030] The steam sterilization device 24 includes a steam sterilization sleeve 241 and a coil 242, which are nested in a ring around the outside of the sampling chamber 2. The steam sterilization sleeve 241 is a double-layered stainless steel sleeve, forming an annular steam channel with uniform width between it and the sampling chamber 2. An air inlet is located at the top of the sleeve, connected to a steam source via a pipe, and a condensate outlet is located at the bottom for discharging condensate. The coil 242 is spirally wound along the axial direction of the steam sterilization sleeve 241, with both its inlet and outlet located near the outer valve 23. Steam enters from the inlet and flows along the coil 242, uniformly heating the sampling chamber before returning to the steam system from the outlet. This structure ensures a closed-loop flow of steam within the sleeve, guaranteeing uniform temperature on the outer wall of the sampling chamber and stable sterilization performance.

[0031] The filter assembly 211 is located between the external valve 23 and the sampling port 21, and is detachably connected to the sampling chamber 2 via a clamp-type quick-release structure. The filter assembly 211 includes a filter support and a filter medium, which can be a stainless steel filter screen or a polyethersulfone filter membrane, sealed to the support by an O-ring. The support has quick-release interfaces at both ends; one end connects to the outlet end of the external valve 23 via a clamp, and the other end connects to the inlet end of the sampling port 21 via a clamp. The clamp-type quick-release structure uses an eccentric cam design, allowing for quick installation and removal by simply turning the handle, without the need for tools, facilitating filter replacement by operators in a sterile environment.

[0032] During sampling, the sampling chamber is first preheated and sterilized by the steam sterilization device 24. After sterilization, the inner valve 22 is opened, allowing the material in the fermentation chamber to flow into the sampling chamber under the pressure inside the tank. After the material fills the sampling chamber, the inner valve 22 is closed and the outer valve 23 is opened. The material flows out from the sampling port 21 after being filtered by the filter assembly 211, completing the sampling. After sampling, the outer valve 23 is closed, and steam is introduced again to sterilize the sampling chamber to ensure that the residual material is completely inactivated.

[0033] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A pollution-free sampling fermentation tank, characterized in that, include: The fermenter body (1) is formed as a cylindrical tube and has a fermentation chamber that runs through it along its axial direction. The sampling chamber (2) is formed as a cylindrical cavity. At least a part of the sampling chamber (2) is located in the fermentation chamber and is connected to the fermentation chamber. Sampling valve groups are provided at both ends of the sampling chamber (2). The material in the fermentation chamber is sampled and tested by opening and closing the sampling valve groups.

2. The pollution-free sampling fermenter according to claim 1, characterized in that, The sampling chamber (2) is arranged horizontally on the fermenter body (1), and the angle between the axial direction of the fermenter body (1) and the setting direction of the sampling chamber (2) is 40-50°.

3. The pollution-free sampling fermenter according to claim 1, characterized in that, The sampling chamber (2) includes: Sampling port (21) is located at one end of the sampling chamber (2) away from the fermenter body (1); An internal valve (22) is provided at one end of the sampling chamber (2) that extends into the fermentation chamber; An external valve (23) is located at one end of the sampling chamber (2) near the sampling port (21), and a sampling cavity is formed between the internal valve (22) and the external valve (23).

4. The pollution-free sampling fermenter according to claim 3, characterized in that, The sampling chamber (2) further includes a steam sterilization device (24), which includes: A steam sterilization sleeve (241) is fitted onto the outer circumferential surface of the sampling chamber to heat the sampling chamber. The coil (242) is nested along the axial direction of the steam sterilization sleeve (241) on the outer circumferential surface of the steam sterilization sleeve (241). The inlet and outlet of the coil (242) are both located at one end of the steam sterilization device (24) near the outer valve (23).

5. The pollution-free sampling fermenter according to claim 3, characterized in that, A replaceable filter assembly (211) is provided between the external valve (23) and the sampling port (21). The filter assembly (211) is detachably connected to the sampling chamber through a clamp-type quick-release structure.

6. The pollution-free sampling fermenter according to claim 1, characterized in that, The sampling chamber (2) is made of stainless steel and is connected to the fermenter body (1) by flange sealing welding.

7. The pollution-free sampling fermenter according to claim 3, characterized in that, The inner valve (22) is a pneumatic diaphragm valve, which is remotely controlled to open and close via a PLC control system.

8. The pollution-free sampling fermenter according to claim 3, characterized in that, The external valve (23) is a manual shut-off valve, and a silicone sealing ring is provided inside the external valve (23).

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