DTU
Client: Technical University of Denmark – Department of Chemical Engineering
Custom-designed fermentation system
The challenge
DTU required a fermentation system in the form of a tank that could be integrated into their pilot plant. The pilot facility is designed for working with GMOs (genetically modified organisms) and serves to illustrate and simulate pharmaceutical and biochemical processes for students in their experimental projects.
The goal was to make the processes as realistic as possible, which meant the fermentation system had to comply with the legislation and hygiene standards required by the industry (GMP requirements). DTU saw in the tender material that Nordic Engineering could meet these standards. The mixing tank to be manufactured for DTU would form part of a larger fermentation and biochemical process.
It was essential that the tank be as versatile as possible, as it would also be used for research and for GMP training courses at DTU. Therefore, it needed to be equipped to handle both predictable and unpredictable processes—quite unlike typical pharmaceutical industry setups, where systems are usually highly specialized.
The fermentation system
The system had to be capable of storing fermentation broths and biochemical products, including large-scale GMO material, and the tank needed to be as fully automated as possible. DTU therefore commissioned a custom-built tank with integrated auxiliary equipment, including heating and cooling capabilities, agitation, various measurement sensors, and automated process control sequences based on preset temperatures.
In addition, the tank had to be designed to ensure effective cleaning and removal of any residual material during emptying or transfer. To maintain standards and hygiene requirements, it was crucial to avoid contamination from residual materials or potential metallic or microbial impurities. For this reason, the tank was constructed to withstand steam sterilization as part of the organism-elimination process.
Process and collaboration
Because the tank and its instrumentation and automation had to be as versatile as possible, specialists at Nordic Engineering were able to propose robust and well-considered technical solutions based on DTU’s specification requirements.
Although Steen Larsen has many years of experience in the industry and in factory construction, he finds Nordic Engineering exceptionally competent:
“Nordic Engineering were excellent to work with—they were highly competent in providing guidance and offering alternative solutions for us to choose from. They were able to present technical alternatives in a visual and detailed manner, so the fact that the collaboration was online posed no problem at all.”
—Steen Larsen, Manager, DTU Chemical Engineering Pilot Plant.
The project spanned nearly one year, from January 2020 to December 2020.
DTU is an international elite technical university founded in 1829 with the mission to “develop and utilize natural and technical sciences for the benefit of society.” DTU is a hub for education, research-based consultancy, and innovation.
The university provides research-based advisory services to Danish authorities and international organizations and is known for transforming research into new technologies through close collaboration among academic partners, industry, and public-sector stakeholders.
The process
How we solved the task
Step 1 – Initial meeting
We began with an initial meeting where we mapped out the challenge, needs, existing conditions, and DTU’s technical requirements. This formed the foundation for the system design.
Step 2 – System calculations
After the initial meeting, we carried out all the necessary calculations for the forthcoming system. These calculations also formed the basis for our pricing.
Step 3 – Design phase
Based on DTU’s specifications and our calculations, we created 3D drawings of the proposed system.
Step 4 – Design presentation and approval
We presented the system drawings, which DTU reviewed and approved following a thorough evaluation.
Step 5 – System manufacturing
Using the production drawings, we procured all components and manufactured the system.
Step 6 – System delivery
We delivered the completed skid system to DTU and performed test runs to ensure full functionality.
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