Each application has specific requirements. That’s why the configuration of your bioreactor makes all the difference.

You probably already know that a bioreactor is a piece of equipment designed to maintain controlled conditions for the growth of microorganisms and cells. Although the operating principle is essentially the same, it is unlikely that a single configuration will effectively meet the requirements of every bioprocess.

While some cultures require high oxygen transfer rates, others demand gentle agitation conditions to preserve cell viability. Certain applications require monitoring of multiple specific parameters, while others rely on particular feeding strategies, temperature control, or lighting systems.

If every application has its own unique requirements, does it make sense to use exactly the same bioreactor configuration for such different processes? In practice, the answer is no.

That is why Tecnal develops customizable bioreactors that allow researchers, research centers, universities, and industries to configure their systems according to the specific needs of each application.

You do not simply choose a bioreactor model—you also select the components that best suit your process. Before choosing a bioreactor, ask yourself a few important questions.

Before choosing a bioreactor, ask yourself a few questions

Before selecting your equipment, it is important to evaluate the specific requirements of your bioprocess.

Consider questions such as:

• Will you need to monitor specific process parameters?
• Does your culture require a particular type of agitation?
• Are the microorganisms sensitive to shear stress?
• Is it important to visually monitor the culture throughout the process?
• Will you need to expand the system in the future by adding new sensors or accessories?
• Will the process require automatic nutrient feeding, pH control, or antifoam dosing?

Answering these questions helps identify which components will truly make a difference in your process. 

When the equipment configuration is not aligned with the application, some features may remain underutilized, while others that are critical to the process may be missing during operation or future system expansions.

A great bioreactor is the combination of multiple components 

When we think of a bioreactor, we usually picture only the culture vessel and the control module. However, process performance depends on several components working together.

The vessel type, agitation system, installed sensors, number of peristaltic pumps, and automation features all have a direct impact on culture efficiency, process reproducibility, contamination reduction, data quality, and overall ease of operation.

For this reason, Tecnal bioreactors have been designed as flexible systems capable of adapting to a wide variety of applications. Below are the customizable configurations available for Tecnal bioreactors.

Culture Vessel: Choose the best option for your application 

The vessel is one of the most important components of a bioreactor. Its material, working volume, and temperature control system directly influence culture performance.

There is no single ideal vessel material—only the material that is best suited for each specific process.

Glass Vessels

Glass vessels provide excellent visibility of the culture, allowing operators to monitor qualitative parameters such as foam formation, turbidity, mixing homogeneity, and aeration efficiency throughout the process.

This makes glass an excellent choice for applications involving bacteria, yeast, cell cultures, and many other microorganisms. Glass vessels are available in both jacketed and single-wall configurations. 

Stainless steel vessels

In addition to their mechanical strength, stainless steel vessels provide superior protection against external light exposure—an important feature for certain biological processes. These vessels are also available in jacketed and single-wall versions.

Hybrid Vessels (Glass and stainless steel)

Hybrid vessels combine the strength of stainless steel with the visibility provided by glass.

They are widely used for cultivating filamentous fungi and other microorganisms that tend to adhere to the vessel walls. Hybrid vessels are available exclusively in jacketed configurations.

Airlift (Pneumatic) Vessels 

Not every process can tolerate mechanical agitation. For these applications, Tecnal also manufactures Airlift pneumatic bioreactors, in which culture circulation is driven solely by aeration, significantly reducing mechanical stress on microorganisms.

This configuration is commonly used for cultivating filamentous fungi, microalgae, cyanobacteria, and other photosynthetic organisms.

In addition, Airlift models can be equipped with LED lighting systems featuring different light spectra, photoperiod control, and PAR sensors for real-time monitoring of light intensity, creating ideal conditions for organisms that depend on light for growth.

Different working volumes 

Tecnal vessels are available in a wide range of working volumes, supporting everything from bench-scale research to pilot-scale applications. 

For process scale-up, 55 L and 170 L pilot vessels are available.

Custom-designed vessels can also be developed to meet the specific requirements of your application.

Temperature control systems 

Tecnal vessels are available with different temperature control systems to ensure process stability and reproducibility.

• Jacketed vessels: A thermal fluid (water or a water-glycol solution) circulates through the vessel jacket for both heating and cooling. Temperature is controlled using a thermostatic circulator.
• Temperature range: 10°C to 70°C.
• Ideal for: fermentation and conventional bioprocesses. 

• Single-wall vessels: An internal cooling coil provides efficient cooling, while a silicone heating blanket delivers precise heating.
• Temperature range: -2°C to 130°C.
• Greater thermal flexibility.
• Ideal for bioprocesses, fermentation and chemical reactions. 

Impellers: The right agitation for every process 

The impeller determines how the fluid moves inside the vessel, directly influencing nutrient distribution, oxygen transfer, solids suspension, and mixing homogeneity.

For this reason, Tecnal offers a wide range of impeller configurations to meet the specific requirements of different bioprocesses. Available options include Rushton and Smith turbines, pitched-blade impellers, marine propellers, anchor impellers, double helical impellers, and several other designs.

Each impeller provides distinct flow patterns, shear characteristics, and mass transfer performance, allowing agitation to be optimized for the specific requirements of each culture.

For low-viscosity fluids:

• Rushton and Smith turbines: High-speed operation (100–1,000 RPM), excellent gas dispersion and efficient mixing of immiscible liquids;
• Four-pitched blade impeller: Efficient solids suspension and excellent mixing of immiscible liquids;
• Marine propeller: High-speed operation (300–1,500 RPM), efficient solids suspension with low shear and ideal for mixing miscible fluids.

For high-viscosity fluids:

• Double Helical impeller: Suitable for highly viscous fluids (20–1,000 Pa·s), low-speed operation (5–100 RPM) and mixed axial and radial flow;
• Anchor impeller: Recommended for viscous fluids (5–50 Pa·s), radial flow pattern and low-speed operation (5–100 RPM).

For shear-sensitive processes:

• For shear-sensitive cultures, the recommended solution is an Airlift bioreactor, where mixing is achieved pneumatically rather than mechanically, minimizing mechanical stress on cells and microorganisms.

Sensors: Monitor the parameters the matter 

Outro benefício dos biorreatores Tecnal é a possibilidade de selecionar os sensores mais adequados para cada aplicação. Os sistemas podem ser configurados com sensores digitais de alta precisão para monitoramento de diversos parâmetros.

Another advantage of Tecnal bioreactors is the ability to select the most suitable sensors for each application. The systems can be configured with high-precision digital sensors to monitor a wide range of parameters.

With direct digital communication, eliminating the need for analog converters, the sensors provide greater signal stability, reduced noise, and improved data reliability. 

• Digital pH sensor (Hamilton): A pressurized, maintenance-free digital pH sensor offering outstanding stability, even after repeated steam sterilization, autoclaving, or CIP (Clean-in-Place) cycles. Its digital technology eliminates signal noise and ensures reliable measurements, even in complex culture media.
• Dissolved oxygen sensor (Hamilton): An optical dissolved oxygen sensor that provides accurate measurements without interference from CO₂ or pH. Because it requires neither electrolyte nor polarization time, the sensor delivers immediate, stable, and highly accurate readings from the moment measurements begin. It features a long-life optical cap (CAP) requiring replacement only after approximately 10 sterilization cycles.
• PT-100 temperature sensor: Provides highly accurate measurements of culture medium temperature with excellent long-term stability. An essential sensor for maintaining the optimal temperature range required for microbial and cell growth.
• Foam sensor: Excessive foam can obstruct exhaust lines and filters, compromising process safety and performance. The foam sensor automatically activates a peristaltic pump to dispense antifoam agent whenever excessive foam is detected, preventing operational problems.

Tecnal bioreactors can also be equipped with additional digital sensors that communicate directly with the PLC via the RS-485 Modbus RTU protocol, including: 

• Viable cell sensor: Measures viable biomass through capacitance (permittivity) technology.
• Conductivity sensor: Industrial-grade, sterilizable four-electrode conductivity sensor. Measurement range: 0.02 to 500 mS/cm.
• Turbidity sensor: Near-infrared (NIR) measurement at 860 nm, featuring a 5 mm optical path length. Measurement range: 0–30,000 NTU
• Methano (CH₄) sensor: Infrared sensor utilizing dual-wavelength technology. Measurement range: 0.5–100% CH₄.
• ORP (Redox) sensor: Platinum ring electrode for oxidation-reduction potential measurements. Measurement range: –1,500 to +1,500 mV.
• Dissolved CO₂ sensor: Non-dispersive infrared (NDIR) technology for continuous dissolved carbon dioxide measurement. Measurement range: 0.5–100% vol.

Depending on the model and application, the system may also include:

• PAR sensor: precise monitoring of light intensity for photosynthetic cultures.
• Pressure sensor: monitors the internal pressure of the bioreactor. Operating range: 0 - 380 mmHg.
• CO₂ and O₂ gas analyzer: Measures the concentrations of carbon dioxide and oxygen in the process gases (measurement ranges: 0 - 5%, 0 - 20%, 0 - 100%) and oxygen (measurement range: 0 - 25%) 

With more than 14 available process ports on the vessel, Tecnal bioreactors offer the flexibility to install the sensors and accessories that best fit your specific application.

Configure your culture feeding strategy 

Every cultivation strategy has its own feeding requirements.

Batch, fed-batch, and continuous processes may require different combinations of nutrients, pH control solutions, antifoam agents, and other process inputs.

For this reason, Tecnal bioreactors can be equipped with up to five independent Watson-Marlow peristaltic pumps (depending on the selected control module), providing complete process flexibility with dosing control based on either pump revolutions or dispensed volume.

The operating principle of a peristaltic pump is simple: rollers compress a flexible tube, pushing the fluid through the system. Since the fluid only comes into contact with the inside of the tubing, the risk of contamination is significantly reduced.

In addition, the system features cascade control functions, allowing selected process parameters to be adjusted automatically according to the culture's behavior, improving process stability and reducing operator intervention.

When you need something completely different: custom bioreactors 

Although the Tecnal bioreactor portfolio includes a wide range of vessels, impellers, sensors, and feeding systems, some projects require even more specialized solutions.

For these applications, Tecnal develops fully customized bioreactors, engineered to meet unique process requirements.

These projects may involve custom vessel designs, integration of specialized sensors, structural modifications, dedicated lighting systems, or any other solution defined according to the application's specific needs.

Backed by a team specialized in bioreactor engineering and development, Tecnal has extensive experience designing and manufacturing fully customized systems. The development process is straightforward:  

1. Understanding Your Requirements: You describe your bioprocess, operating constraints, and technical requirements.
2. Technical Evaluation: Our engineering team evaluates the project's feasibility, identifies technical limitations, and analyzes the most suitable solutions.
3. Engineering Design: A customized technical solution is developed based on the identified process requirements.
4. Manufacturing and Validation: Tecnal designs, manufactures, assembles, integrates, and internally validates the complete system before delivery.
5. Delivery: You receive a bioreactor specifically engineered for your application.

Tecnal has successfully developed custom bioreactors for a wide variety of applications, including:

• Chemical reactors
• Enzymatic hydrolysis reactors
• Mini bioreactors for enzymatic digestion
• Bioreactors for mining research
• Reactors for polymers and highly viscous media
• Reactor/mixers for granular carbon
• 150 L reactors for yeast biomass research and production
• Other fully customized process solutions  

A bioreactor that evolves with your laboratory 

A laboratory's requirements naturally evolve over time. New research projects emerge, processes become more sophisticated, and new technologies are incorporated into everyday laboratory operations.

Tecnal bioreactors have been designed with this evolution in mind, allowing future system expansion without the need to replace the entire platform.

As your needs grow, you can: add new process sensors, install additional peristaltic pumps, use different compatible vessel configurations, upgrade the control software, expand system functionality with new accessories and automation features.

For laboratories planning to scale up their processes, Tecnal also offers pilot-scale bioreactors, enabling a smooth transition from laboratory research to pilot production.

As a result, your equipment grows alongside your project, providing greater flexibility while maximizing the return on your investment over the long term.

Would you like to learn more about bioreactor technology and explore the Tecnal bioreactor portfolio? Contact one of our specialists to find the ideal solution for your application.