What Makes a Bioreactor Custom?
True customization goes far beyond simply choosing a vessel size or adding an extra port. At DCI INC., pharmaceutical bioreactor design focuses on process-specific design, such as tailoring the height-to-diameter ratio to match the mass transfer requirements of your specific culture. We look at the unique metabolic demands of your cell lines to determine the optimal impeller type and placement. These cGMP-compliant vessels also feature complex piping configurations and sterile sampling ports designed to withstand the rigorous cleaning and sterilization cycles required in modern pharmaceutical production.
The Types of Stirred-Tank Bioreactors
Our Stirred-Tank Bioreactors (STRs) support a wide range of upstream applications. Whether you are conducting initial research or managing a massive production run, we have engineered systems that fit perfectly into your workflow, including:
- Bench-Top STRs: These units are engineered for small-scale research and development, allowing for precise parameter optimization before committing to larger volumes.
- Industrial-Scale STRs: We build these specifically for large-scale production, with capacities reaching thousands of liters for high-demand manufacturing.
- Hybrid Systems: These offer the best of both worlds by combining robust stainless steel bioreactors with single-use liners, providing the structural integrity of steel with the flexibility of disposables.
Key Customizable Features
Each biological process has its own variables that need careful control to keep cells healthy. DCI INC. can custom-design every part of the vessel to match your process, so you have full control over your cell environment. Some of the features of a custom bioreactor can be found below.
Agitation Systems
When it comes to your mixing and agitation system, too much shear force can damage cells, while too little force leads to an inconsistent mixture. Our custom builds regularly feature PharMix® impellers. We use custom-made blades and place them at precisely calculated angles. This results in finely controlled mixing systems that allow you to optimize things like cell growth and nutrient distribution.
Temperature Control
Keeping a stable temperature is essential for getting the best product yield. We use ASME code-stamped dimple jackets and half-pipe jackets for even heat transfer. This prevents hot or cold spots from affecting your batch, even when temperatures change quickly.
Material Selection
The material that makes up your bioreactor is as important as its design. 316L stainless steel is great for most uses, but we also offer Hastelloy® C-22 for high-saline or corrosive processes. Picking the right alloy helps prevent corrosion and keeps your runs clean.
Applications in Pharma and Biotech
Our custom vessels support many important processes in the life sciences. From new gene therapies to established protein production, DCI INC.’s pharma and biotech vessels help manufacturers and labs reach their goals safely and efficiently.
Gene Therapy
Gene therapy production needs very high purity to avoid cross-contamination. We can make vessels with a 10 Ra electropolish finish, creating a smooth surface that stops protein carryover. This careful finishing keeps your batches as pure as possible.
Monoclonal Antibodies (mAbs)
Making monoclonal antibodies often needs high cell densities, which means you need excellent oxygen transfer. Our bioreactors are built for high-yield production and meet top surface finish standards for these demanding processes. We design the vessel shape to support the right mass transfer rates for healthy cells.
Scale-up Solutions
Scaling up from a pilot study to full production is often challenging because scaling is not always straightforward. DCI INC. designs pilot bioreactors to work just like full-scale vessels, making the transition smooth. This consistency removes guesswork and lowers the risk of costly mistakes.
Advantages of Custom-Built Bioreactors
Custom-built bioreactors let you adjust every part of your process for the best results. Standard options often mean you have to compromise, but a custom vessel gives you better control and quality from the start. With DCI INC., you can trust your equipment to work reliably every time.
Compliance and Quality Standards
In regulated industries, having the right documentation is as important as the equipment. As a leading bioreactor manufacturer in the USA, DCI INC. gives you all the needed documents, like Material Traceability Reports (MTRs) and Welding Procedure Specifications (WPS) for FDA validation. We take pride in our ability to always follow ASME BPE (Bioprocessing Equipment) standards.
Get a Quote From DCI INC. Today
Your process is unique, so your equipment should be as well. DCI INC. custom bioreactors are built to meet the special needs of pharma and biotech, helping you get better yields and reliable results. Don’t settle for subpar equipment. Work with a partner who builds for you. Contact us now to get a quote.
