Industrial fermentation and blood product technology form the backbone of modern biotechnology and pharmaceutical manufacturing. From antibiotics and vitamins to plasma substitutes and blood derivatives, these technologies ensure the large-scale availability of essential healthcare products. Unit 5 focuses on fermentation methods, large-scale fermenter design, production of key biotechnological products, and the collection and handling of blood products. This article presents these concepts in a structured, news-style format suitable for pharmacy and life-science students.

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Fundamentals of Fermentation Technology

Fermentation Methods and General Requirements

Fermentation is a biochemical process in which microorganisms convert substrates into valuable products under controlled conditions. Based on oxygen requirement, fermentation is classified into aerobic and anaerobic processes. Industrial fermentation demands strict control of parameters such as temperature, pH, nutrient concentration, oxygen supply, and contamination prevention to ensure consistent product quality.

Culture Media and Their Importance

The success of fermentation depends heavily on the composition of the culture medium. Media provide carbon sources, nitrogen sources, minerals, vitamins, and growth factors essential for microbial metabolism. Media may be simple, complex, or synthetic, depending on the organism and product. Optimization of media composition directly influences yield and cost-effectiveness.

Equipment, Sterilization, and Aeration

Fermentation equipment includes seed tanks, fermenters, air compressors, and downstream processing units. Sterilization is critical to eliminate unwanted microorganisms and is commonly achieved using steam under pressure.
Aeration supplies oxygen to aerobic cultures and is achieved through spargers and controlled airflow. Adequate oxygen transfer is essential for high biomass and product formation.

Stirring and Agitation

Agitation ensures uniform distribution of nutrients, oxygen, and microorganisms. Mechanical stirrers prevent sedimentation and maintain homogeneity, directly affecting microbial growth and productivity.

Large-Scale Fermenter Design and Control Systems

Design of Industrial Fermenters

Large-scale fermenters are typically stainless-steel vessels designed to withstand pressure, temperature, and corrosion. Key design features include:

1. Agitators and baffles for efficient mixing

2. Spargers for aeration

3. Sampling ports for quality monitoring

4. Jackets or coils for temperature control

Fermenter Controls

Modern fermenters are equipped with automated control systems to monitor and regulate critical parameters such as pH, temperature, dissolved oxygen, foam formation, and nutrient feed rate. These controls ensure reproducibility, maximize yield, and reduce batch failure in large-scale operations.

Industrial Production of Biotechnological Products

Production of Penicillins

Penicillin is produced by Penicillium chrysogenum through submerged aerobic fermentation. The process involves optimized carbon sources, controlled aeration, and precise pH management. After fermentation, penicillin is recovered through solvent extraction and purification.

Citric Acid Production

Citric acid is produced using Aspergillus niger under highly controlled conditions. Excess carbohydrate supply and limited nitrogen enhance citric acid accumulation. The product is widely used in pharmaceuticals, food, and beverages.

Vitamin B12 Production

Vitamin B12 is produced by microorganisms such as Propionibacterium and Pseudomonas. The fermentation process is complex and requires cobalt ions for synthesis. Vitamin B12 is essential for treating anemia and neurological disorders.

Glutamic Acid Production

Glutamic acid, a key amino acid, is produced using Corynebacterium glutamicum. Controlled limitation of biotin promotes glutamic acid excretion into the medium. It is widely used in pharmaceuticals and nutrition.

Griseofulvin Production

Griseofulvin, an antifungal antibiotic, is produced by Penicillium griseofulvum. The fermentation process is optimized for secondary metabolite production, followed by extraction and crystallization.

Blood Products: Collection, Processing, and Storage

Collection of Whole Human Blood

Whole blood is collected from healthy donors using sterile, anticoagulant-containing blood bags. Donor screening ensures safety and prevents transmission of infectious diseases.

Processing of Blood Products

Collected blood is separated into components such as red blood cells, plasma, platelets, and cryoprecipitate through centrifugation. Component therapy allows targeted treatment and efficient use of donated blood.

Dried Human Plasma

Plasma is processed and dried to improve stability and storage life. Dried plasma is reconstituted before use and is essential in emergency situations such as shock and severe blood loss.

Plasma Substitutes

Plasma substitutes, including dextrans and gelatin solutions, are used to maintain blood volume when plasma is unavailable. These products help stabilize blood pressure and circulation in trauma and surgical patients.

Storage Conditions

Proper storage is critical to maintain the efficacy of blood products. Red blood cells are stored at 2–6°C, platelets at room temperature with agitation, and plasma at sub-zero temperatures. Strict adherence to storage guidelines ensures patient safety.