Integrated control system for advanced microbial and cell culture applications. Engineered for precision, scalability, and 24/7 industrial reliability.
Overview
BAILUN500 series bioreactor is an integrated control system available both for microbial and cell culture applications for stainless steel vessels, standard with the capacities from 10L to 200L. Customized bioreactors are available for engineering solutions up to 400ton. As part of the comprehensive bioreactor portfolio, those stainless steel fermenters can be easily integrated as a component of multi-stage systems.
The standard BAILUN500 Series bioreactor guarantees a short 2-month lead time, featuring automatic SIP, precise temperature/pH/DO/agitation control, jacket heating, and gas regulation via rotameter or TMFC. It is highly customizable to fit various budgets, offering advanced options like a lid lifting device, CIP, automatic vessel pressure control, dual pH/DO monitoring, expanded gas mixing, and exhaust analysis.
BAILUN500 series with O2-enrichment gassing strategy, 6-blade Rushton impellers, and Pt100 temperature sensor optimized for microbial fermentation.
BAILUN500 series with advanced gas flow, CO2 control, 3-blade segment impellers, and sparger + overlay gassing for mammalian and insect cell culture.
BAILUN500 single configuration delivers complete individual control with digital PLC, 10″ touchscreen, and all standard peristaltic pump management.
BAILUN500 dual configuration controls two same or different volume vessels independently — greatly increasing flexibility and experimental throughput.
control tower with integrated software. Culture vessel with functional ports and pipelines
The control tower features at least four built-in peristaltic pumps, with different functions for microbial research (BAILUN500) and cell culture (BAILUN500) respectively. Meanwhile, it’s available both in single (BAILUN500) and dual vessels (BAILUN500) configuration. It can control two same or different volume vessels to work independently at the same time, which greatly increases the flexibility and efficiency.
comes with low noise agitation motor and top drive mechanical sealing. The vessel is designed to eliminate blind spots, with Tank accuracy ≤ 0.4μm, large open lid, and bottom sanitary radial discharging valve, which makes it easy to clean and maintain. With 2:1 or 3:1 aspect height to diameter ratio and 3-layer impellers, the culture vessel is ideal for homogenous heat and mass transfer.
Available in single or dual vessel setups with standard incremental capacities ranging from 10L to 200KL. Standard configurations guarantee a short lead time, while fully customized systems remain extensive options.
Driven by a robust industrial control system featuring a 10-inch color touchscreen interface. It provides comprehensive measurement and real-time control over pH, DO, temperature, foam, agitation speed, vessel pressure, and gas mixing strategies.
Equipped with automatic Sterilization in Place (SIP) as standard. It includes a specialized filter to protect the system from air contamination, with options for an integrated automatic Cleaning in Place (CIP) system or a mobile CIP unit with an independent controller.
Offers superior gas mixing utilizing up to four flow meters, with Thermal Mass Flow Controllers (TMFC) available as an option. Features 4 integrated peristaltic pumps per vessel with standard fixed speed and optional variable speed control.
Customizable with optional sensor measurements for level, vessel weight, and storage vessel weight. It supports automated substrate addition, dual pH/DO sensors, an upper controller, an automated cover lifting device, and your choice of bottom mechanical or magnetic agitation.
Supports optional online analytical detection arrays for exhaust gas, redox potential, turbidity, $CO_2$, online live cell monitoring, cleanliness, and online methanol/ethanol content analysis. All systems come with full qualification documentation available.
Available culture vessels from 10L, 20L, 30L, 50L, 100L and 200L , with a total volume aspect ratio of (H:D) 2:1 or 3:1, up to 75% working volume. Material: SS316L, Surface treatment: mirror polishing; Tank accuracy ≤ 0.4um, external surface accuracy <0.8um. Large angle observation mirror for liquid level in the tank, which is resistant to corrosion, high temperature and high pressure Culture vessel’s design temperature: 150°C, design pressure: 0.3Mpa, jacket pressure: 0.4Mpa LED light for convenient viewing inside the culture tank.
Easy to operate, in-situ sterilization includes fermenter, intake filter and pipeline, exhaust pipeline; Sampling valve, inoculation port and discharge valve can be sterilized manually or automatically.
Air filter to prevent contamination air from getting to the system. With exhaust gas discharge condenser, specially designed exhaust gas discharge pipeline, slope ≥3°, no accumulation of liquid and no bacteria.
The BAILUN500 series system offers advanced CIP solutions. The culture vessel is prepared with CIP interface. It also allows a mobile CIP cleaning station with its own control system, allowing the operator to selectively, effectively, repeatedly and automatically clean the system, including fermentation tanks, piping and valves etc.
Top mechanical drive stirring allows good sealing performance, with high-performance stirring paddles, and different types of paddles can be used according to characteristic requirements. Options: Bottom mechanical stirring or bottom/top magnetic stirring
Application-appropriate spargers are available for microbiology and cell culture. The system selects corresponding gassing strategies for different sizes and types of fermenters. And the gas flow rate can be adjusted manually by a precision rotameter or automatically by an optional TMFC.
Utilizing one air flow path, the flow meter intuitively indicates and controls sparger flow rate. An optional mass flow controller can be integrated to control and measure the flow range by manual regulation or automatically in combination with a DO controller.
Utilizing two flow paths for air and O2 flow, the flow meter intuitively indicates and allows manual adjustment of the sparger flow rate. O2 is pulsed through a solenoid valve and flows only as needed to maintain the Dissolved Oxygen (DO) set point. A mass flow controller can be integrated to measure and control the total gas flow range by manual adjustment or automatically combined with a DO controller.
Up to 5 gas flow paths. Air goes into overlay through a flow meter and a solenoid valve. At the same time, solenoid valves select air, O2, N2 and CO2 to flow to the sparger. There are two ways to adjust the flow rate. The flow meter can intuitively set the flow rate of each gas path independently and use the solenoid valve as the gas path switch. The optional mass flow meter can automatically measure and control the gas path flow, which makes it possible to set and stabilize the overlay and sparger.
Strict quality control process, like Tank flaw X-ray detection, air tightness testing, sensors testing, sterilization procedure test…Furthermore, we also have relevant patents and provide related documents like, IQ, OQ, PQ, SAT, FAT…
| Name | Description | Brand |
|---|---|---|
| Tank body | The tank body is made of TISCO stainless steel 316L+304 jacket+304 thermal insulation layer | |
| Stirring motor | AC geared motor | SEW |
| Tank Accessories | Observation mirror, process interface and other accessories | |
| Stainless steel control box | 304 stainless steel chassis matte brushed treatment | |
| Bioreactor PLC controller | Control module | Siemens |
| filter pressure reducing valve | AW30-03BG-A | |
| Pressure Switch | 3C-IS10M-30 | |
| Pressure relief valve | Release pressure 0.27MPa | |
| Relay | Relay | Schneider |
| Pressure gauge | Sanitary diaphragm pressure gauge 0-0.4Mpa, 0-0.6Mpa | |
| Pressure Sensor | 0-6bar | HUBA |
| Temperature electrode | Class A precision, SS316L, electropolished 0.4um, 0-150°C | Germany |
| peristaltic pump | Automatic, manual, segmented control | Watson marlow |
| Diaphragm valve | Matching according to pipe diameter | BURKERT |
| Tank Bottom Diaphragm Valve | AISI 316L Wall-mounted Diaphragm, Pneumatic, DN20-DN10 | BURKERT |
| Pneumatic Diaphragm Valve | DN15 | BURKERT |
| Thermal Mass Flow Meter | For high precision control | BURKERT |
| Valve Island | Valve automatic control | |
| One-way valve | Prevent reverse flow of gas | |
| Stainless steel filter shell | 316L stainless steel filter sleeve, single core 3 inch | |
| Hydrophobic filter element | Hydrophobic Sterile Filter, 3" | |
| Spray ball | 316L, 360° cleaning, 3/4" BPE standard, pin type | XINLAN |
| PH electrode | InPro3253/SG/120 | Mettler, Hamilton |
| PH cable | AK9/1m | Mettler, Hamilton |
| DO electrode | InPro6860/12/120 | Mettler, Hamilton |
| DO cable | VP8-ST/1m | Mettler, Hamilton |
| Aseptic sampling valve | Individually sterilizable 316L | |
| Sterile feeding Valve | Individually sterilizable, four-valve manifold | BURKERT |
| Cooling solenoid valve and circulating pump | Grundfos |
| Model | BAILUN500-M1-10L | BAILUN500-M1-20L | BAILUN500-M1-30L | BAILUN500-M1-50L | BAILUN500-M1-100L | BAILUN500-M1-200L |
|---|---|---|---|---|---|---|
| Culture vessel total volume | 11.5L | 21.2L | 28.8L | 51.3L | 119.5L | 198L |
| Working volume | 8.6L | 15.9L | 21.6L | 38.5L | 89.6L | 148.5L |
| H:D radio 2:1 | 3:1 | | | |||||
| Control Unit | Single vessel control [Option: twin configuration (dual vessels) or more] | |||||
| Digital controller, color display with touch screen | ||||||
| Control Capabilities | ||||||
| Temperature, DO, agitation speed | ||||||
| Foam sensor, foam alarm | ||||||
| Vessel pressure measurement | auto control | | | |||||
| Auto sterilization in place | ||||||
| Control PH by adding acid/alkali | ||||||
| Gassing strategy | Air / O2, sparger | |||||
| Flow meter | Rotameter [optional TMFC] | |||||
| Low noise stirring motor | ||||||
| Peristaltic pump | 4 for acid, alkali, antifoam, feed [Up to 6 pumps]; fixed speed [optional variable] | |||||
| Process Control System | ||||||
| Temperature control system | Closed loop system for heating and cooling | |||||
| Automatic sterilization pipe with valve | ||||||
| Culture Vessel | Jacketed Stainless Steel Vessel with Sight Glass and Top Mechanical Agitation | |||||
| Stirrer shaft with top single mechanical seal | ||||||
| Impeller | 6-blade Rushton impeller, 3pcs | |||||
| Stainless steel filter housing for air inlet and exhaust filter | ||||||
| Pressure gauge | [0~0.4Mpa] | |||||
| Aeration tube with ring sparger | ||||||
| Exhaust Cooler | ||||||
| 4-baffles [removable] | ||||||
| Resterilizable sampling valve | ||||||
| Lamp for vessel illumination | ||||||
| Bottom discharging valve | ||||||
| Integrated pipeline | ||||||
| Storage bottles [4pcs] | ||||||
| PH electrode, cable | ||||||
| DO electrode, cable | ||||||
| Temperature sensor Pt 100 | ||||||
| Foam electrode, cable | ||||||
| Options | ||||||
| Stirrer shaft with double mechanical seal | single magnetic seal | | | |||||
| Mobile CIP station with independent controller | ||||||
| Cleaning in Place | ||||||
| Vessel weight measurement | auto control | | | |||||
| Auto vessel pressure control | ||||||
| Lid lifting device | ||||||
| Dual PH sensors | Dual DO sensors | | | |||||
| Variable speed pump | ||||||
| Cleanliness detection | ||||||
| Turbidity detection | ||||||
| Redox detection | ||||||
| Exhaust detection | ||||||
| Liquid level monitoring | ||||||
| Methanol and ethanol content online detection | ||||||
| Qualification Documents | ||||||
| Model | BAILUN500-M1-10L | BAILUN500-M1-20L | BAILUN500-M1-30L | BAILUN500-M1-50L | BAILUN500-M1-100L | BAILUN500-M1-200L |
|---|---|---|---|---|---|---|
| Culture vessel total volume | 11.5L | 21.2L | 28.8L | 51.3L | 119.5L | 198L |
| Working volume | 8.6L | 15.9L | 21.6L | 38.5L | 89.6L | 148.5L |
| H:D radio 2:1 | 3:1 | | | |||||
| Control Unit | Single vessel control [Option: twin configuration (dual vessels) or more] | |||||
| Digital controller, color display with touch screen | ||||||
| Control Capabilities | ||||||
| Temperature, DO, agitation speed | ||||||
| Foam sensor, foam alarm | ||||||
| Vessel pressure measurement | auto control | | | |||||
| Auto sterilization in place | ||||||
| Control PH by adding acid/alkali | ||||||
| Gassing strategy | Air / O2, sparger | |||||
| Flow meter | Rotameter [optional TMFC] | |||||
| Low noise stirring motor | ||||||
| Peristaltic pump | 4 for acid, alkali, antifoam, feed [Up to 6 pumps]; fixed speed [optional variable] | |||||
| Process Control System | ||||||
| Temperature control system | Closed loop system for heating and cooling | |||||
| Automatic sterilization pipe with valve | ||||||
| Culture Vessel | Jacketed Stainless Steel Vessel with Sight Glass and Top Mechanical Agitation | |||||
| Stirrer shaft with top single mechanical seal | ||||||
| Impeller | 6-blade Rushton impeller, 3pcs | |||||
| Stainless steel filter housing for air inlet and exhaust filter | ||||||
| Pressure gauge | [0~0.4Mpa] | |||||
| Aeration tube with ring sparger | ||||||
| Exhaust Cooler | ||||||
| 4-baffles [removable] | ||||||
| Resterilizable sampling valve | ||||||
| Lamp for vessel illumination | ||||||
| Bottom discharging valve | ||||||
| Integrated pipeline | ||||||
| Storage bottles [4pcs] | ||||||
| PH electrode, cable | ||||||
| DO electrode, cable | ||||||
| Temperature sensor Pt 100 | ||||||
| Foam electrode, cable | ||||||
| Options | ||||||
| Stirrer shaft with double mechanical seal | single magnetic seal | | | |||||
| Mobile CIP station with independent controller | ||||||
| Cleaning in Place | ||||||
| Vessel weight measurement | auto control | | | |||||
| Auto vessel pressure control | ||||||
| Lid lifting device | ||||||
| Dual PH sensors | Dual DO sensors | | | |||||
| Variable speed pump | ||||||
| Cleanliness detection | ||||||
| Turbidity detection | ||||||
| Redox detection | ||||||
| Exhaust detection | ||||||
| Liquid level monitoring | ||||||
| Methanol and ethanol content online detection | ||||||
| Qualification Documents | ||||||
| Culture Vessel | 10L | 20L | 30L | 50L | 100L | 200L |
|---|---|---|---|---|---|---|
| Space requirement Single [m] [W × H × D] |
0.8×1.3×0.8 31.5×51.2×31.5 |
0.9×1.6×0.8 35.4×63×31.5 |
0.9×1.7×0.9 35.4×67×35.4 |
1.0×1.9×0.9 39.4×74.8×35.4 |
1.0×2.1×1.0 39.4×82.7×39.4 |
1.2×2.5×1.0 47.2×98.4×39.4 |
| Space requirement Twin [m] [W × H × D] |
1.4×1.3×0.8 55.1×51.2×31.5 |
1.6×1.6×0.8 63.0×63×31.5 |
1.6×1.7×0.9 63.0×67×35.4 |
1.9×1.9×0.9 74.8×74.8×35.4 |
2.0×2.1×1.0 78.7×82.7×39.4 |
2.4×2.5×1.0 94.4×98.4×39.4 |
| Culture vessel weight Single [kg] | 45 | 72 | 77 | 109 | 169 | 245 |
| Ambient temperature | Relative humidity | 5~40°C | 85% | |||||
| Utilities Requirements [Reference] | ||||||
| Process Air, M | C | 3bar | 3bar | |||||
| O2 Sparger, M | C | 3bar | 3bar | |||||
| N2 Sparger, M | C | N/A | 3bar | |||||
| CO2 Sparger, M | C | N/A | 3bar | |||||
| Utility steam, Pressure | Steam | 3bar | 20Kg/h | 3bar | 20Kg/h | 3bar | 20Kg/h | 3bar | 20Kg/h | 3bar | 20Kg/h | 3bar | 40Kg/h |
| Cooling water, Pressure | Flow | 3bar | 5L/min | 3bar | 5L/min | 3bar | 5L/min | 3bar | 15L/min | 3bar | 25L/min | 3bar | 50L/min |
| CIP, Pressure | Flow | 1.5bar | 33L/min | 1.5bar | 33L/min | 1.5bar | 33L/min | 1.5bar | 33L/min | 1.5bar | 43L/min | 1.5bar | 70L/min |
| Instrument air | 6bar | |||||
| Power supply | 208 VAC or 400 VAC | |||||
| Control Unit | ||||||
| Controller | Industrial PC or PLC | |||||
| Display | Operation | Touch Panel 10" | Touch screen | |||||
| Communication | Ethernet network | |||||
| Housing Material | SUS304 | |||||
| Dimension | Weight | 400×300×1500mm | 45Kg | |||||
| External Connection | ||||||
| USB | 1 x data copy and export | |||||
| Other connections | 1 x RS485 or upon request | |||||
| Sensor type | PT100 | |||||
| Gassing System | ||||||
| Microbial application | Max. total flow rate: 1.5vvm | |||||
| Cell culture application | Max. total flow rate: Sparger 0.1vvm | overlay 1vvm | |||||
| Both application | Max. total flow rate: 1.5vvm | |||||
| Flow meter | Air calibrated: 1.2bar 20°C | |||||
| Flow Rate | 0.5SLPM, 1.0SLPM, 2.5SLPM, 5.0SLPM, 10SLPM, 25SLPM [customizable] | |||||
| Accuracy | +/- 1% FS | |||||
| Peristaltic pumps | 4 pumps [Up to 6 pumps] | |||||
| Constant-rate pump | 60rpm [Watson Marlow] | |||||
| Rotation speed, Bore | 0.5 mm (1/50”) | 0.8 mm (1/32”) | 1.6 mm (1/16”) | 3.2 mm (1/8”) | 4.8 mm (3/16”) | 8.0 mm (5/16”) |
| Flow range [ml/revolution] | 0.02 | 0.05 | 0.22 | 0.81 | 1.66 | 6.64 |
| Temperature Control | ||||||
| Temperature control system | Closed-loop constant temperature system with circulation pump, electric heater, water chiller [optional] | |||||
| Temperature control range | 8°C above coolant to 40°C above ambient [0 to 65°C absolute temperature] | |||||
| Culture Vessel | 10L | 20L | 30L | 50L | 100L | 200L |
| H:D ratio | 2:13:1 | 2:13:1 | 2:13:1 | 2:13:1 | 2:13:1 | 2:13:1 |
| Total volume | 11.5L | 21.2L | 28.8L | 51.3L | 119.5L | 198L |
| Working volume | 8.6L | 15.9L | 21.6L | 38.5L | 89.6L | 148.5L |
| Minimal working volume | 2.9L | 5.3L | 7.2L | 12.8L | 29.9L | 49.5L |
| Agitation speed [rpm] | 5~1000 | 5~1000 | 5~1000 | 5~800 | 5~700 | 5~400 |
| Motor power [Kw] | 0.75 | 1 | 1 | 0.75 | 1.5 | 2.2 |
| Impeller to vessel diameter [6-blade Rushton impeller] |
0.40.4 | 0.40.4 | 0.40.4 | 0.40.4 | 0.40.4 | 0.40.4 |
| Impeller to vessel diameter [3-blade segment impeller] |
0.5N/A | 0.5N/A | 0.5N/A | 0.5N/A | 0.5N/A | 0.5N/A |
| Lid ports | 1 × sight glass for illumination 1 × sampling port |
1 × inoculation port 1 × port for exhaust |
4 × port for feeding 1 × agitation flange |
|||
| Upper side wall | 1 × vertical sight glass 1 × port for cooling water out |
1 × aeration port 1 × port for rupture disc |
||||
| Lower side wall | 1 × sampling port | 4 × sensor | ||||
| Bottom | 1 × sampling valve | 1 × port for cooling water in | ||||
| Vessel design | Jacketed stainless steel vessel with torospherical bottom, vertical sight glass and agitation system | |||||
| Material [proooduct wetted parts] | SUS316L | Borosilicate glass | EPDM [FDA approved] | |||||
| Surface finish [wetted part | outer surface] | Ra <0.4 µm | Ra <0.8 µm | |||||
| Pressure design criteria, vessel | jacket | 0~3bar @ 150°C | 0~3bar @ 150°C | |||||
| Sensors | Measurement | Resolution | ||||||
| Dissolved oxygen | Polarographic or optical | 0–150% | 1% | +/- 0.1% | |||||
| PH | Gel filled | 2–12 | +/- 0.01 pH | |||||
| Foam | Level | High Foam | Conductive probe | |||||
| Temperature | PT100 | 0~150°C | +/- 0.1°C | |||||
| Pressure | Piezoresistive sensor | -0.5–2 [barg] | 1 mbar | |||||
| Regulatory compliance | CE; ASME optional; UL optional | |||||
