Lab-Pilot Scale Water Bath Fermenter | EasyReal
The EasyReal Lab-Pilot Scale Water Bath Fermenter combines precision heating, efficient agitation, and advanced control technology in a compact design. Its double-layer stainless-steel vessel features a water jacket that distributes heat evenly through the bath medium, avoiding local hot spots and ensuring uniform fermentation.
Inside the vessel, a high-shear agitator or normal impeller agitator mixes viscous liquids, suspensions, or milk-based substrates without damaging sensitive cultures. The system supports programmable profiles for multi-stage fermentation — such as heating, holding, and cooling — which can be executed automatically through PLC recipes.
Temperature sensors, pH probes, and optional DO (dissolved oxygen) transmitters enable closed-loop control for critical fermentation parameters. Data logging and trend visualization allow users to track performance, making the fermenter ideal for both academic research and industrial pilot-scale testing.
All product-contact surfaces are food-grade SUS304 or SUS316L, with sanitary piping and valves to ensure aseptic operation. The entire system can be connected to optional utilities such as a steam generator for sterilization or a chiller for controlled cooling phases.
The Lab-Pilot Scale Water Bath Fermenter serves a wide range of industries and R&D institutions developing fermented beverages, dairy alternatives, and bioactive products.
Typical applications include:
• Yogurt, kefir, and cultured dairy formulations
• Kombucha and probiotic beverages
• Enzyme and microbial fermentation trials
• Plant protein fermentation and enzymatic hydrolysis
• Flavor and aroma compound development
• Juice and tea-based fermentation prototypes
Its flexible configuration supports different vessel volumes — from 2 L to 50 L, making it suitable for universities, food enterprises’R&D center, pilot plants, and corporate innovation labs. Each setup can simulate scaled-down versions of full industrial fermenters, giving process engineers accurate insights before scale-up.
By maintaining stable temperature and pH control, the system ensures batch-to-batch consistency and repeatable sensory quality — key to successful commercialization.
Fermentation trials demand accurate thermal and mixing control to protect cultures and prevent contamination. Unlike simple stirred tanks, the EasyReal Water Bath Fermenter uses indirect heating through circulating water. This eliminates direct steam contact, avoiding over-temperature zones that can destroy probiotics or denature proteins.
Raw materials such as milk, soy protein, or fruit extract can vary in viscosity and solids content, influencing heat transfer. EasyReal engineers design vessel geometry, agitation speed, and jacket area accordingly. A safety interlocks prevent operation without sufficient water or pressure balance.
This attention to hygiene and control helps R&D teams meet food safety standards (HACCP, ISO22000) and regulatory audits for experimental or pre-commercial production.
Core sizing
• Vessel working volumes: 2 L / 5 L / 10 L / 20 L / 30 L / 50 L (working volume = 70–85% of total).
• Lid style: clamp-down sanitary lid with sight-glass and tri-clamp ports.
Thermal system (water bath)
• External thermostatic circulating water bath (heating 20–95 °C; with chiller option down to 4–10 °C).
• Temperature Control: Pt100 sensor in product + bath sensor.
• Materials: SUS304 or SUS316L contact surfaces; jacket/coil dedicated to water loop (no direct steam in product).
Agitation & rheology
• Impeller options: marine (low-shear) or anchor (medium viscosity).
• Optional scraper arms for higher solids slurries (only when needed).
• Variable-speed drive with sanitary mechanical seal.
Sensors & aseptic features
• Standard: temperature (Pt100).
• Options: pH (food-grade probe), DO (for yeast/aerobic trials).
Controls & data
• Siemens PLC + 7"/10" HMI, recipe steps (ramp/hold/cool), trends, alarms, batch IDs, USB/Ethernet export.
• Interlocks: low-water in bath, over-temperature, lid/door switch, pump dry-run protection.
Utilities & build
• Power: single-phase 280 V, 50/60 Hz (others on request).
• Cooling water or closed-loop chiller (recommended for fast cooldown).
• Compressed air (for valves/air overlay if selected).
• Mobile skid/trolley with locking casters; small footprint for lab benches/pilot rooms.
Recommended bundles
• Lab and Pilot bundle (2–50 L): water-bath + chiller, impeller, PHE, pH + DO options, PLC/HMI.
The fermentation workflow typically follows the sequence below, adjustable by product and formulation:
1. Material Preparation – Raw milk, juice, or plant substrate is preheated and homogenized.
2. Inoculation – Starter cultures or microbial inoculants are introduced aseptically.
3. Water Bath Heating – The circulating water bath gradually raises product temperature to setpoint.
4. Fermentation Holding – The system maintains steady pH and temperature for defined hours.
5. Agitation and Sampling – Continuous or intermittent stirring ensures homogeneity; samples can be withdrawn safely.
6. Cooling Phase – Water bath and optional chiller lower product temperature to stop fermentation.
7. Discharge and Cleaning – Final product is drained.
Each stage is logged through the PLC for complete traceability and reproducibility across experiments.
A complete Lab-Pilot Scale Water Bath Fermenter system from Shanghai EasyReal Machinery Co., Ltd. integrates several modular units designed to ensure stability, hygiene, and precision at every stage of the process.
1. SUS304 or SUS316L Fermentation Vessel (Water-Bath Jacketed)
Conical-bottom, tri-clamp ports, mirror-polished wetted surfaces. Indirect heating via circulating water prevents hot spots and protects cultures.
2. Thermostatic Circulating Water Bath / Chiller
Closed loop provides precise ramp/hold/cool profiles (≈20–95 °C; with chiller to ≈4–10 °C). Bath and product sensors maintain tight setpoints.
3. Variable-Speed Agitator (Marine / Anchor)
Low-shear mixing for dairy/plant bases; anchor when viscosity rises. Sanitary mechanical seal and CIP-capable design.
4. Sensor Suite (Food-Grade)
Pt100 temperature (standard); optional pH, DO for process control and data. Ports for sterile sampling and calibration.
5. PLC + HMI Control Cabinet (Siemens)
Recipes, interlocks, alarms, trends, data export, and remote-assist option. One operator oversees multi-stage fermentation confidently.
6. Electric Steam Generator (Optional, for SIP)
Provides saturated steam only to the product side for sterilization when required by validation protocols.
7. Skid/Trolley & Safety Interlocks
Compact mobile frame, locking casters, low-water protection for bath, over-temp cutoff, lid/door switch.
The Lab-Pilot Scale Water Bath Fermenter supports a wide range of input materials and fermentation styles, making it one of the most versatile systems in EasyReal’s R&D lineup.
Material Compatibility
• Dairy and plant-based liquids: milk, soy, oat, almond, coconut
• Juice and tea bases: apple, grape, kombucha, herbal infusions
• Microbial broths: enzymes, probiotics, flavor yeasts
• Protein slurries: fermentation of plant or single-cell proteins
Output Options
• Fermented milk and non-dairy beverages
• Enzyme-rich extracts and probiotic cultures
• Alcohol-free or low-alcohol fermented teas
• Flavor and aroma precursors for food formulation
The modular setup allows researchers to adjust process parameters rapidly between different recipes. Batch-to-batch repeatability ensures data reliability for formulation optimization.
EasyReal also offers pilot-scale validation services — testing raw materials and process recipes under actual production conditions to verify scale-up potential. This provides R&D teams with reliable data to transition from laboratory results to commercial lines with confidence.
The EasyReal Smart Control Platform brings industrial automation into laboratory-scale equipment. The system features:
• Siemens PLC and HMI interface for recipe-based operation and intuitive visualization.
• Automatic parameter regulation for temperature, pH, agitation, and water-bath circulation.
• Alarm and interlock functions that protect against dry heating, overpressure, or power interruptions.
• Data recording and export via USB or Ethernet, enabling traceable experiment reports.
• Remote monitoring (optional) allowing engineers to access fermentation trends through network connection.
• Modular scalability for future integration with other EasyReal pilot modules — UHT sterilizer, deaerator, or aseptic filler — forming a complete mini pilot line.
With this control logic, one operator can oversee complex multi-stage fermentation sequences. Setpoints remain stable even during long holding periods, and every trial produces consistent results aligned with industrial performance expectations.
From concept to commissioning, Shanghai EasyReal Machinery Co., Ltd. provides end-to-end support for laboratory and pilot-scale fermentation systems.
Our engineering team assists clients through each step:
1. Define scope and target product (fermented beverage, enzyme culture, plant-based yogurt).
2. Design layout and P&ID customized for your lab or pilot space.
3. Confirm utilities such as water, steam, and power connections.
4. Assemble and test all components in EasyReal’s factory before shipment.
5. On-site commissioning or remote validation via video link.
6. Training & documentation for daily operation, maintenance, and safety.
With more than 25 years of experience and projects in 30+ countries, EasyReal ensures your investment delivers high performance, long service life, and reliable R&D outcomes.
Contact us today to discuss your project or request a test run in our pilot lab.
Email: sales@easyreal.cn
Website: https://www.easireal.com/contact-us/
