The present invention relates to the field of fermentation. In particular, the present invention relates to a method and apparatus for production of products by use of living cells or active components derived from such cells using a bioreactor having a built in gas distributor and a specific system/device for handling foam formed in the process. The invention also relates to a bioreactor comprising: a reaction chamber having a fermentation zone and a foam settling zone, wherein the reaction chamber is arranged such that the foam settling zone is spaced from or physically separated from the fermentation zone so as to reduce the effect of activity in the fermentation zone on foam in the settling zone. The separation of the fermentation zone from the activity of the fermentation zone encourages settling of the foam. The invention also provides a method of forming a bioreactor comprising: overlapping two flat, flexible sheets of material; and causing said two sheets to adhere to each other in selected areas so as to define a reaction chamber. This is a particularly cost-effective way to produce a single use, disposable reactor.

A reactor system is provided for improved fermentation of a gaseous substrate through the introduction of a secondary loop to a forced-circulation loop reactor. The reactor comprises a primary loop through which fermentation broth comprising a gaseous substrate is circulated through a riser segment and a downcomer section by a loop pump. Downstream of the loop pump a portion of fermentation broth is withdrawn from the downcomer section and is directed to the top of the reactor via a secondary loop. Further provided is a method for improving the mass transfer of a gaseous substrate to a fermentation broth in a fermentation vessel comprising a secondary loop. Further provided is a method for reducing foam in the headspace of a fermentation vessel comprising a secondary loop.

A foam sensor system includes a flexible bag comprised of a polymeric material and bounding a compartment. A foam sensor assembly is mounted on the flexible bag and includes a foam contact disposed within the compartment of the flexible bag. A ground assembly is mounted on the flexible bag and includes a ground contact disposed within the compartment of the flexible bag, the foam sensor assembly and the ground assembly being configured so that an electrical potential can be applied between the foam contact and the ground contact.

The aspects of the disclosed embodiments generally relate to an apparatus which allows for the controlled addition of antifoam to the foam present in the headspace of a disposable single-use bioreactor in a reliable manner. The aspects of the disclosed embodiments also generally relate to a method of using such apparatus which allows for the controlled addition of antifoam to the foam present in the headspace of a disposable single-use bioreactor in a reliable manner. The aspects of the disclosed embodiments generally relate to antifoam systems, methods and apparatus, and more particularly, to an antifoam device operably connected to a single use biobag.

A device and method for detecting the level of foam in a reactor vessel monitors the intensity of the light of the movement of the light detected by a camera. The camera monitors at least one light source positioned inside the reactor vessel or viewable through the reactor vessel.

A system for producing a hydrophobic chemical includes circulating biofilm bioreactors for synthesizing the hydrophobic products and continuous extraction into an organic solvent phase. Various configurations can be employed for assembling the bioreactors into a production module. Extraction operations can be conducted in one or more extraction vessels. In some cases, product and solvent are separated using membrane separation techniques, with solvent being rerouted to the extraction vessel(s). Methods for the biotransformation of feedstocks into chemical products also are described.

System for detecting at least one presence of foam of a medium in a bioreactor plant, wherein the system comprises: a bioreactor plant having at least one disposable container for receiving the medium that may comprise the foam; andat least two capacitive sensor units which are attached at at least two different situating positions of the bioreactor plant, wherein the capacitive sensor units each comprise at least one electrode system for capacitive measurement and are able to detect the presence of foam at the at least two situating positions on the basis of the capacitive measurement; and wherein the capacitive sensor units are designed to transmit captured data relating to the presence of foam to at least one monitoring unit for monitoring, open-loop and/or closed-loop control of foam formation in the bioreactor plant on the basis of said data.

The present invention provides improved bioprocessing systems and methods for cell culture using the improved bioreactors, e.g., batch-fed or perfusion bioreactor cell culture systems for production of monoclonal or bi-specific antibodies, which are modified to include one or more membrane gas transfer modules in place of a sparger- or microsparger-based aeration systems to better regulate the levels of critical gases in a bioreactor cell culture, e.g., the dissolved levels of O.sub.2 and CO.sub.2, even at high cell densities, without subjecting the cells to bubble-burst associated cell death.

The present invention provides improved bioprocessing systems and methods for cell culture using the improved bioreactors, e.g., batch-fed or perfusion bioreactor cell culture systems for production of monoclonal or bi-specific antibodies, which are modified to include one or more membrane gas transfer modules in place of a sparger-or microsparger-based aeration systems to better regulate the levels of critical gases in a bioreactor cell culture, e.g., the dissolved levels of O.sub.2 and CO.sub.2, even at high cell densities, without subjecting the cells to bubble-burst cell death.

A foam sensor device is used for monitoring foam within a vessel. The sensor (e.g. accelerometer) is encapsulated inside a water-tight, sterilizable, shell, which floats on a liquid contained. In one example, the foam sensor device includes an accelerometer for detecting and measuring rotation and movement of the foam sensor device and generates movement data based on the detected movement. During a learning or calibration process, sensor data (e.g., movement data) from the foam sensor device is analyzed and classified using machine learning and/or signal processing methods to extract features indicative of different possible foam statuses, including varying levels of foam, or no foam and generate models for the different statuses. During normal operation, the foam sensor device transmits sensor data to an analyzer containing the pre-calibrated models, which determines whether there is foam or not. Based on the foam status, a pump controller adds anti-foam solution.