Fermentation plants Revamp

In addition to being the representative of BioEngineering in Israel, Modcon Systems has a vast experience in fermentation systems revamps and renovations. The system to be repaired is transferred to Modcon Systems‘ workshop and undergoes a thorough treatment, depending on it’s condition.

Among other operations, and according to the requirements, we perform:

  • Thorough renovation of all the relevant peripheral systems (such as the air supply system)
  • Renovation of the structure (rust removal by sand-blasting and plates repainting and/or replacing)
  • Renovation of the main board, including tags and signposting
  • Replacement of all obsolete analogical systems with new digital systems
  • Addition of electrodes and probes as required

Modcon Systems installs the best equipment and instruments in the renewed system, tailor made to the customers demands: pH & DO combined transmitter, pH electrode with temperature compensation, O2 electrode with temperature compensation, Pt 100 probe and transmitter for temperature measurement, a programmable controller, computerized touch screen for display, control and data logging etc.

Moreover, according to its service-oriented characteristics, Modcon Systems takes an integral part in installation and running of the renewed system and also with consulting and service later on.

Sample Projects

1. Renovation of a 20L fermentor for Amgal Chemicals

Amgal Chemicals purchased two fermenters with 20L total volume (One from Bio Lafitte and the other from Bioengineering), in order to create one automatic, active fermentor with computerized control system. The purpose of the project was: Adjusting the computerized control system and process piping to the costumer’s needs.

As part of the revamp, the following changes were made:

  • Replacement of manual valves to electrical valve actuators
  • Change and renovation of the old structure, so that it can adapt to the process.
  • Adjusting double mechanical seals to the agitation systems.
  • Adaptation of the existing modern control system based on Siemens PLC and HMI to the customer’s needs by writing and designing automated procedures for sterilization, cultivation and other methods that are necessary to the process.
  • renovation of instruments and replacement if necessary
  • Design and installation of a new control cabinet, which includes all the necessary control accessories.
  • Adding graphs to the computerized system, which show online process data, including history saving system.
  • Adding alarm system with history event saving.

Modcon Systems takes an integral part in installation and running of the renewed system and also with consulting and service later on.

2. Renovation of a 30 years old 16L NBS fermentor for Sigma Aldrich Israel

In 2002 the fermentor has been mechanically renovated by Modcon- systems’ team as a result of recurrent infections. The renovation prevented the infection and the fermentor went back to work for about 12 years. During these years, the fermentor operated manually with an old analog control system. The current upgrade project has been carried out in order to make the fermentor completely automatic, as requested.

This revamp included, among others:

  • Replacement of manual valves to electrical valve actuators
  • Additional control loops for air flow, pressure control and rotation speed control.
  • Replacement of transmitter and electrodes for dissolved oxygen and pH from Mettler-Toledo to new and improved model
    (M-800): for this purpose, the existing oxygen and pH electrode has been replaced in optical DO electrode and pH smart electrode, ISM.
  • Replacement of the existing control system in a more modern system , based on Siemens PLC and HMI.
  • Design and installation of a new control cabinet, which includes all the necessary control accessories.
  • Design and writing automatic procedures for sterilization, cultivation and operation.
  • Adding graphs to the computerized system, which show online process data, including history saving system.
  • Adding alarm system with history event saving.

The system has been installed successfully in the client’s site to his complete satisfaction.

 

  Before                                  After     

                                             Sigma Revamp- Before              Sigma Revamp- After         

 

 

 

 

 

3. Renovation of a 200L NBS fermentor for Biovac

This revamp included, among others:

  • Detailed design of the pipeline and the process
  • Adding control loops for: air flow, carbon dioxide, oxygen and pressure and replacement of all the necessary electrodes.
  • Adding automated glucose control loop.
  • Adding computerized control system, based on Siemens PLC and HMI.
  • Design and installation of a new control cabinet, which includes all the necessary control accessories.
  • Replacement of manual valves to electrical valve actuators
  • Replacement of old pipeline in a new and suitable one for the process.
  • Design and writing automatic procedures for sterilization, cultivation and operation.
  • Adding graphs to the computerized system, which show online process data, including history saving system.

The project was designed and implemented within a very short time, with the fool cooperation of the customer.

 

4. Installation of a new control system to a 25 years old 1000L fermentor for Sigma Aldrich Israel

The installed system includes a programmed controller and a control panel with a touch screen. The control and electricity systems were renewed and fitted.

Before

After

More customers of Modcon Systems for revamped fermentation systems:

  • Minrav Industries (Biological division)- Revamp of a 17 years old 150L fermenter
  • The Veterinary Magid Institute- In the department for Fish Diseases Research, temperature and pH controls were added to a second-hand fermenter that was purchased overseas and arrived “naked”. The work included: connections of the system to water, steam and air supplies and also to the drain system; assembly of the system, activation and follow-up.