Solid State Fermentation Plant with Transparent Bags
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Solution Overview
Problem
Existing solid state fermentation technologies face challenges in maintaining sterility, operational complexity, and high costs due to complex structures and lack of visual control, which affects the productivity and reliability of microorganism culture production.
Innovation Solution
A multifunctional solid state fermentation plant with a simplified structure featuring transparent, autoclave plastic bags on a scaffolding system for sterility and temperature control, an automatic inoculum injection device, and a system for controlled air flow and sterilization, allowing for visual monitoring and reduced operation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex structures with multiple chambers and filters are used in fermentation bags, then sterility control is improved, but device complexity increases and operation costs rise
Solution Approach 1:
The patent removes the complex internal subdivision elements (diaphragms, multiple filters, nozzles) from the fermentation bag, retaining only the essential function of sterility control through a simplified single-chamber design with external filter connection, thereby reducing device complexity while maintaining sterility reliability
Solution Approach 2:
The patent employs disposable fermentation bags with integrated filter units that can be sterilized and discarded after use, eliminating the need for complex reusable structures with multiple components, thus reducing both device complexity and operation costs while ensuring sterility
2Reliability
If closed structure fermenters with multiple plates are used, then sterility is maintained, but visual control capability is lost and pollution detection becomes difficult
Solution Approach 1:
The patent uses transparent plastic fermentation bags that allow visual observation of the fermentation process while maintaining sterility through their sealable structure, enabling both visual control and sterility maintenance simultaneously without requiring complex transparent windows or observation ports
Solution Approach 2:
The transparent bag structure provides continuous visual feedback on the fermentation state and potential contamination, allowing operators to detect and respond to pollution events immediately, thereby maintaining sterility through active monitoring while preserving visual control capability
3Productivity
If liquid phase fermentation apparatus with swinging platforms is used, then mixing is improved, but applicability to solid state fermentation is reduced and structural complexity increases
Solution Approach 1:
The patent designs a simple horizontal bag structure that can be adapted for both liquid phase and solid state fermentation by changing the substrate type and aeration method, eliminating the need for complex swinging platforms while maintaining versatility across different fermentation modes through basic structural simplicity
Solution Approach 2:
The patent uses controlled air flow through the horizontal bag to achieve mixing and substrate aeration in solid state fermentation, replacing mechanical swinging platforms with pneumatic action, thereby improving adaptability to solid state fermentation while maintaining productivity through effective gas-solid contact
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The plant achieves high productivity, absolute sterility, and low investment costs by ensuring sterility and visual control, while maintaining efficient temperature and air flow management, enhancing the production of microorganisms and secondary metabolites.
Implementation Method 1
said shelves (1), in variable number, depending on the plant size, that are provided with an interspace or a coil wherein a thermostabilizing fluid is made to flow, so to thermostabilize, contemporarily, the bag (7)
Implementation Method 2
by the steam autoclave (24) for the sterilization ad cooking, if any, when substrata are used that need to be cooked
Implementation Method 3
said series of filter (15) for sterilized air being formed by a metallic container with a replaceable sterilizing cartridge (16)
Implementation Method 4
by the automatic device or gun (26) for the inoculum injection, in an automatically predetermined quantity, into the hermetically closed bag (7)
Implementation Method 5
a pump for the delivery of said fluid to the shelves (1); by control and regulation instruments and by suitable distribution and return manifolds of said fluid
Implementation Method 6
wherein a thermostabilizing fluid is made to flow, so to thermostabilize, contemporarily, the bag (7)
Data Source
Figure 1~3
Figure 4~5
AI summary
A solid state fermentation plant for the production of vital microorganism cultures in sterile conditions and with high concentration is described. Said plant, in comparison with other similar plants and known devices, is characterized by a remarkable structural simplicity and a high reliability.