Sterilizable Bench-top Bioreactor KLF

Bench-Scale Bioreactor KLF: The Only In Situ Sterilizable System on the Market

The Bioengineering KLF bench-scale bioreactor is the only glass fermenter sterilizable in situ available on the global market, offering precise control and complete sterilization with agitated medium. This technological uniqueness represents a decisive advance in laboratory bioprocesses.

Studies published in ScienceDirect on in situ sterilization confirm the superiority of this approach: "with in situ sterilization, the medium is placed in the bioreactor, mixed and then sterilized and cooled in the same location", eliminating the "inherent contamination hazards" during transfers. 

"Small device. Big discoveries." - This is the motto that defines this Swiss bench-scale bioreactor, ideal for downscaling applications in the food, pharmaceutical, and research industries. In this technical guide you will discover why the KLF represents the definitive choice for laboratories seeking excellence in bioprocesses.

What is the KLF Bench-Scale Bioreactor and How It Works

The KLF bench-scale bioreactor uses borosilicate glass vessels in different capacities and operates with advanced control technology. Furthermore, this system offers total flexibility for different types of cultivation through specific configurations.

Main Technical Specifications

Specification	Value
Processing Capacity	1.6L / 2.0L / 2.5L
Available Total Volumes	2.4L / 3.1L / 3.7L
Vessel Type	Borosilicate glass or stainless steel
Agitation System	Bottom agitation with mechanical seal or magnetic coupling
Agitation Control	60-2300 rpm
Cultivation Temperature	Maximum 80°C
Pressure Control	Optional up to 1 bar
Maximum Configuration	Up to 6 bioreactors per control unit

Note: Specifications based on the official technical documentation from Bioengineering AG. For specific applications, always consult the updated technical datasheets.

On the other hand, the bottom agitation system allows greater operational stability, while the brushless DC motor ensures precise speed control without variations.

Unique Differentiators of the KLF Bench-Scale Bioreactor

This bench-scale bioreactor offers exclusive characteristics that make it a global leader in its category. Therefore, it represents much more than simple laboratory equipment.

Documented Exclusive Features

1. Only In Situ Sterilizable System on the Market
   
   

   • Sterilization with agitated medium
   • Temperature continuously measured and recorded
   • Process comparable to industrial fermenters
     
     

2. Resterilizable Drain Valve
   
   

   • Guaranteed complete emptying
   • Sterile sampling during the process
   • Steam-sterilizable
     
     

3. Optional Pressure Control
   
   

   • Up to 1 bar of controlled pressure
   • Suitable for downscaling applications
   • Simulation of industrial conditions
     
     

4. BioSCADA Software Included
   
   

   • License included with the equipment
   • Functionality for process control
   • Simultaneous control of up to 6 units

Versatile Configurations of the Bench-Scale Bioreactor

This bench-scale bioreactor offers unparalleled flexibility through multiple specialized configurations. Additionally, it allows perfect adaptation for each specific application type.

Types of Available Agitators

Agitator Type	Application	Characteristics
Rushton (Disc Blade)	Microbial cultivation	High turbulence, radial mixing
Marine (Propeller)	Cell culture	Low shear, axial mixing
Pitched Blade	Mixed applications	Optimized axial mixing

Specialized Aeration Systems

• Vent Tube: Basic aeration for simple cultivations
• Ring Sparger: Efficient gas distribution
• Sinter Sparger: Micro-aeration for sensitive cultivations
• Bubble-Free Gassing: Gas transfer without bubbles for cell culture

Vessel Options

Borosilicate Glass Vessel:

• Total transparency for visualization
• Resistance to thermal shock
• Ease of cleaning and sterilization

Stainless Steel Vessel (up to 5L):

• Greater operational robustness
• Expanded volume capacity
• Compatibility with higher pressures

Exclusive Advantages of In Situ Sterilizable Glass

The choice of in situ sterilizable borosilicate glass for the KLF bench-scale bioreactor is not accidental. According to reactor technology experts, glass reactors offer "excellent visibility, chemical resistance, and durability at a reasonable cost", fundamental characteristics for precision bioprocesses.

Why Glass is Superior for Bench-Scale Bioreactors

Total Transparency for Visual Control: Transparency allows "watching the process without any interference through the help of a graphical interface", enabling direct visual monitoring of the cultivation without interrupting the sterile process.

Absolute Chemical Inertness: Glass is inert and "does not react with the materials being used in the reaction, preventing unwanted impurities". Unlike stainless steel, glass eliminates any risk of contamination from metal leaching.

Ease of Cleaning and Maintenance: "Cleaning and maintenance of glass reactors are easy, which is crucial to prevent cross-contamination". The smooth, non-porous surface of glass allows complete sterilization and visual validation of cleaning.

In Situ Sterilization: The Decisive Differentiator

Comparative studies show that "with in situ sterilization, the medium is placed in the bioreactor, mixed and then sterilized and cooled in the same location", eliminating contamination risks during transfers. This process, exclusive to KLF in the glass bioreactor market, offers:

• Elimination of Transfers: Zero risk of contamination during movement
• Operational Efficiency: Significant reduction of "preparation time between fermentations"
• Simplified Validation: Single, controlled process facilitates GMP documentation
• Resource Economy: Lower steam and energy consumption compared to external sterilization

Industrial Applications of the KLF Bench-Scale Bioreactor

This bench-scale bioreactor perfectly meets the downscaling demands of multiple industries. In this way, it offers a complete solution for process development and optimization.

Application Sectors

Pharmaceutical Industry:

• Bioprocess development
• Cultivation condition optimization
• Process validation before scale-up
• Biocompatibility studies

Food Industry:

• Probiotic fermentation
• Starter culture development
• Fermentation process optimization
• Microbiological quality control

Research and Development:

• Microbial metabolism studies
• Screening of operational conditions
• Development of new biotechnological products
• Toxicity and efficacy assays

Available Specialized Configurations

Plant Cell Reactor:

• Specific configuration for plant cell cultivation
• Controlled conditions for secondary metabolite production
• Aeration system adapted for sensitive cells

Fixed-Bed Reactor:

• Cell and enzyme immobilization
• Continuous bioconversion processes
• Higher cell density and productivity

Integrated Control Systems in the Bench-Scale Bioreactor

The KLF bench-scale bioreactor includes an advanced control system that monitors all critical parameters. In this way, it ensures ideal conditions throughout the cultivation process.

Integrated Control Systems in the Bench-Scale Bioreactor

The KLF bench-scale bioreactor includes a control system that monitors critical parameters according to technical documentation. In this way, it offers controlled conditions during the cultivation process.

Complete Control and Measurement Parameters

Parameter	Sensor	Precision	Characteristics
Agitation Speed	Magnetic encoder	±2%	Real-time control
Temperature	Pt100 probe	±0.1°C	Sterilizable, fast response
pH	Gel electrode	±0.02	Sterilizable, low maintenance
Dissolved Oxygen (pO2)	Optical probe	±1% + 4 ppb	No oxygen consumption
Antifoam/Level	Conductive probe	On/off	Automatic detection

Optional Parameters (Depending on Configuration):

• Pressure: Pressure transducer with ±0.1% precision
• Redox Potential: ORP electrode
• Optical Density: Turbidity sensor
• Weight/Consumption: Integrated scale
• Exhaust Gases: O2/CO2 analyzer

Note: Precisions based on official technical documentation. Specific configurations may vary according to model and selected options.

Additionally, all data is automatically recorded by the BioSCADA system for later analysis.

Aeration Configurations of the Bench-Scale Bioreactor

This bench-scale bioreactor offers total flexibility in gas control and cultivation atmosphere. Therefore, it serves from basic applications to complex processes requiring multiple gases.

Advanced Gas System of the Bench-Scale Bioreactor

This bench-scale bioreactor offers unparalleled gas control with up to 6 configurable individual lines. Furthermore, it allows the use of pulsed valves or mass flow controllers for maximum precision.

Available Gas Configurations

Basic System:

• 1 gas line with manual control
• Pulsed valve for on/off control
• Rotameter for flow visualization

Advanced System:

• Up to 6 independent gas lines
• Mass Flow Controllers (MFC) for precision
• Automatic control via BioSCADA
• Supported gases: Air, O₂, CO₂, N₂

Advantages of the Multi-Gas System

1. Total Flexibility: Configuration for any process type
2. Absolute Precision: Control up to 0.1% of full scale
3. Complete Automation: Programming of gas profiles
4. Integrated Safety: Alarms and interlocks

Integrated Pump Systems

The KLF bench-scale bioreactor includes up to 6 peristaltic pumps integrated into the control unit, plus one additional external pump. Consequently, it offers total capacity for dosing and transfer.

Pump Capabilities

• Fixed Pumps: For continuous acid/base dosing
• Variable Pumps: For controlled feeding and harvest
• External Pump: For large volumes or special applications
• Automatic Control: Full integration with control system

Filtration Systems

• Inlet Filters: Glass with 99.9999% efficiency for 0.1 µm particles
• Outlet Filters: Sterilizable along with the system
• Exhaust Condenser: Stainless steel with water cooling

Complete Technical Specifications of the KLF Bench-Scale Bioreactor

This bench-scale bioreactor combines high-quality materials with Swiss precision engineering. Consequently, it offers exceptional durability and reliability.

Materials and Construction

Component	Material	Characteristics
Main Vessel	Borosilicate glass	Resistant to thermal shock
Contact Components	Stainless steel 316L	Roughness Ra ≤0.8 µm
Seals	EPDM, PTFE, Silicone	Chemical compatibility
Lid and Bottom	Stainless steel 316L	Precision machining

Dimensions and Weight (According to Technical Documentation)

Model	Height (mm)	Width (mm)	Net Weight (kg)	Gross Weight (kg)
KLF 2.4L	1065	510	75	98
KLF 3.1L	1065	510	76	99
KLF 3.7L	1065	510	76	99

Installation Requirements (Data from Technical Manual)

Power:

• Supply: 230V 50/60Hz or 110V 50/60Hz
• Maximum consumption: 1400W (230V) or 800W (110V)
• Protection: 10A fuse (230V) or 16A fuse (110V)

Cooling Water:

• Connection: Nipples for 6/1 mm hose
• Required flow: 2-4 L/min
• Pressure: 0.6-2 bar

BioSCADA Software for Bench-Scale Bioreactor

The control system of this bench-scale bioreactor uses professional BioSCADA software that transforms data into actionable information. Furthermore, it allows simultaneous control of multiple units.

Main BioSCADA Features

1. Customized Interface
   
   

   • Main screen customized for system visualization
   • Insertion of setpoints and process values
   • PID parameters for controllers
     
     

2. Data Visualization
   
   

   • Real-time trends
   • Historical data with scalable timeframe
   • Calculated consumption rate for actuators
     
     

3. Advanced Programming
   
   

   • Control cascades
   • Automated process profiles
   • Calibration of inputs and outputs
     
     

4. Process Management
   
   

   • Integrated alarm system
   • Detailed event list
   • Batch processing
   • Recipe programming

System Capabilities

• Simultaneous control: Up to 6 bioreactor units
• Compatibility: Windows system
• Connectivity: USB, RS232, 4-20mA interfaces
• Storage: Complete data history

Types of Agitators for Bench-Scale Bioreactor

This bench-scale bioreactor offers different types of agitators to optimize each specific application. In this way, it ensures maximum efficiency in mass transfer and mixing.

Available Agitators

Agitator Type	Diameter (mm)	Application	Characteristics
Flat Blade Disc (2x)	40-48	Microbial cultivation	Radial mixing, high turbulence
Propeller (1x)	48-66	Cell culture	Axial mixing, low shear
Segmented Pitched Blade	48-66	Special applications	Optimized axial mixing

Therefore, choosing the correct agitator is fundamental for the success of your bioprocess.

Dosing and Transfer Systems

The KLF bench-scale bioreactor includes versatile systems for nutrient addition and sample collection. Additionally, it offers options for continuous cultivation and perfusion.

Peristaltic Pump Modules

Primary Module (Included):

• 2 fixed-speed pumps
• 1 reversible variable-speed pump
• 3 sets of tubing and clamps

Secondary Module (Optional):

• 2 additional fixed-speed pumps
• 1 additional variable-speed pump
• Expansion of dosing capacity

Sampling Systems

• Needle System: GL32 glass tube for hygienic sampling
• SteriCap System: Sterile connection without needles
• Bottom Valve: Sterile drainage and sample collection

Upgrade and Expansion Options

This bench-scale bioreactor was designed with total modularity, allowing future expansions as your needs evolve. Consequently, it represents a long-term investment.

Available Upgrade Kits

1. Additional Gas Modules
   
   

   • Individual configuration of 1-6 gas lines
   • Thermal mass flow controllers
   • Gases: Air, O₂, CO₂, N₂
     
     

2. Advanced Measurement Systems
   
   

   • Redox potential probe (ORP)
   • Optical density sensor (turbidity)
   • Scales for gravimetric measurement
     
     

3. Auxiliary Equipment
   
   

   • Chiller for cooling water
   • Exhaust gas analyzer (O₂/CO₂)
   • BioVap steam generator

Why Choose the KLF Bench-Scale Bioreactor

This bench-scale bioreactor represents the ideal choice for laboratories seeking excellence in bioprocesses. Additionally, it combines Swiss tradition in bioengineering with cutting-edge technology.

Main Benefits

For Research and Development:

• Guaranteed reproducibility of results
• Total configuration flexibility
• Easy scale-up to larger systems

For Quality Control:

• Complete process validation
• Total data traceability
• Compliance with international standards

For Pilot Production:

• Small-scale production capacity
• Process parameter optimization
• Validation before industrial scale-up

Therefore, the KLF bench-scale bioreactor offers a complete solution for your microbial and cell cultivation needs, combining Swiss precision with operational ease.