Innovative hydrodynamic engineering for intelligent bioreactor fermentation: advanced mixing strategies to enhance bioprocess performance

The efficiency and scalability of industrial fermentation processes largely depend on the optimization of hydrodynamic conditions within bioreactors. However, conventional approaches to mixing design are frequently based on simplified model fluids that inadequately represent the complex rheological and multiphase characteristics of real fermentation media. This limitation often leads to inaccurate process optimization and reduced transferability from laboratory to industrial scale. The present study introduces an innovative hydrodynamic engineering approach for intelligent fermentation systems by integrating advanced mixing strategies with realistic biological media. Hydrodynamic performance was comparatively investigated in Newtonian fluids, non-Newtonian carboxymethylcellulose (CMC) solutions, and Saccharomyces cerevisiae suspensions using an original mechanically stirred bioreactor equipped with two different impeller configurations (perforated paddle and anchor) operated over a broad range of agitation speeds (50–300 rpm).

The proposed method demonstrates that mixing performance is governed by the synergistic interaction between fluid rheology, impeller geometry, and operating parameters. Unlike conventional model systems, real microbial suspensions exhibit distinct hydrodynamic behavior that requires adaptive agitation strategies. In particular, the anchor impeller significantly improved macromixing efficiency, suspension homogeneity, and biomass circulation under heterogeneous conditions, highlighting its potential for intelligent process optimization.

The innovative contribution of this work consists in establishing a hydrodynamic design framework capable of supporting adaptive and knowledge-based optimization of fermentation processes, enabling improved process control, enhanced productivity, and more reliable scale-up. These findings provide valuable engineering principles for the development of next-generation bioreactors and smart bioprocesses applicable in industrial biotechnology, pharmaceutical manufacturing, and sustainable bioproduction.