FINAL YEAR PROJECT

REPORT :- 3
Enhancing Bioprocess : Semi-Automatic
Fermenter
Guide :- Prof. Dr. C. L. Ladekar
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OUR TEAM

VISHWARAJ PATIL HRISHIKESH KARPE SAURABH MANE​ ABHISHEK KASURDE

120B1G183 120B1G173 120B1G179 120B1G174

GROUP ID :- 57
 GUIDANCE
3

Industrial Guidance :- ECORISE Agro-Science Industries, Shirala.

CONTENTS
• Literature Survey
• Design Calculations
• Fabrication and Manufacturing of setup
• Costing
• ​Experimentation and Results
• Conclusion
• Individual contribution
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LITERATURE SURVEY
• Microorganisms:

Pseudomonas fluorescence:
Optimal growth temperature: 25°C-30°C
Preferred agitation speed: 150-250 rpm
Industry-standard microbial count: 1 x 10^8 CFU/Ml

Bacillus subtilis:
Optimal growth temperature: 30°C-37°C
Preferred agitation speed: 200-300 rpm
Industry-standard microbial count: 1 x 10^8 CFU/mL
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• Shaft Structure and Design:

Material:
Stainless steel, chosen for durability and corrosion resistance.
Design:
Each fan is aligned on the same centerline but offset from
each other.
Offset design enhances mixing efficiency by creating
turbulence, ensuring thorough mixing of the biofertilizer
mixture.

Using three tilted blade fans results in

approximately a 2.09% increase in efficiency compared to
using four straight blade fans.
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DESIGN CALCULATIONS
Motor mount Diameter:

Given:

Weight of motor = 15 kg

Outer diameter of the vessel = 15.8 inches

Weight-to-Diameter Ratio Calculation for Motor Mount:

To determine the weight-to-diameter ratio, we can calculate the

weight that 1 inch of diameter needs to support based on the
motor's weight.

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟(𝑘𝑔)
Weight-to-Diameter Ratio ={ }
𝑀𝑜𝑡𝑜𝑟 𝑚𝑜𝑢𝑛𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟(𝑖𝑛𝑐ℎ𝑒𝑠)

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟(𝑘𝑔)
Motor Mount Diameter = { }
𝑊𝑒𝑖𝑔ℎ𝑡−𝑡𝑜−𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑟𝑎𝑡𝑖𝑜
 Standard weight to diameter ratio is 2Kg/inch 8

15 𝑘𝑔
Motor Mount Diameter = { }
2 𝑘𝑔/𝑖𝑛𝑐ℎ

Motor Mount Diameter = 7.5 inches

Diameter of each cylindrical support is given below :

Diameter of each cylindrical support

𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑠𝑢𝑝𝑝𝑜𝑟𝑡𝑒𝑑 𝑏𝑦 15 𝑘𝑔
={ }
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑦𝑙𝑒𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑠𝑢𝑝𝑝𝑜𝑟𝑡𝑠

7.5 𝑖𝑛𝑐ℎ𝑒𝑠
Diameter of each cylindrical support = { }
4

Diameter of each cylindrical support = 1.875 inches

Rounded off, the diameter of each cylindrical support is

approximately 1.5 inches.

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FABRICATION AND MANUFACTURING OF SETUP

1. Motor Mount:

Upon finalizing the design parameters, we liaised with the aluminium fabricators to
convey our design requirements effectively. We shared the exact dimensions, material
specifications for the motor mount, ensuring alignment with our design intent.
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FABRICATION AND MANUFACTURING OF SETUP

The motor mount was strategically positioned and welded onto the
fermenter's lid. The placement was optimized to ensure that the motor aligns
perfectly with the agitator system, facilitating seamless operation. The welds
were executed with precision, ensuring a strong and durable bond between
the motor mount and the fermenter's lid.

2. Rotating shaft:
Equipped with the necessary tools and expertise, we embarked on the
fabrication process of the rotating shaft in the welding workshop. The
stainless steel rods were cut to the required length, followed by precision
machining to achieve the desired dimensions
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The individual components of the rotating shaft were welded together

meticulously to form a single, continuous shaft. Utilizing TIG welding
techniques, we ensured strong and clean weld joints that maintain the shaft's
structural integrity and alignment during operation.
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3. Control Pannel:
The control panel serves as the nerve centre of the semi-automatic fermenter,
regulating its operation and providing real-time monitoring capabilities. To
design and fabricate a control panel tailored to our fermenter's requirements,
we collaborated with an electric solutions workshop. Leveraging spare parts
from the old auto clave provided by Ecorise Agro-Science Industries, we
innovatively crafted a new control panel that integrates additional
functionalities for enhanced control and monitoring.
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Upon inspecting the spare parts from the old auto clave, we identified
components that could be repurposed for our fermenter's control panel.
Collaborating with the electric solutions workshop, we sketched a design that
would integrate these components while incorporating new features for
improved functionality.
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4. Final Setup:
The fermenter integrates all the meticulously designed components
seamlessly. The motor mount securely anchors the motor to the lid, ensuring
stable agitation. The rotating shaft, fabricated with precision in our
workshop, efficiently transmits rotational energy to the blades for optimal
mixing. The control panel, innovatively crafted with repurposed spare parts
and new components, provides intuitive control and real-time monitoring
capabilities.
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The fermenter is designed to operate with efficiency and reliability. The

agitator system, powered by the motor, ensures thorough mixing of the
biofertilizer mixture, promoting consistent quality and efficacy. The
temperature control mechanism, facilitated by the control panel, maintains
the optimal temperature within the fermenter, supporting the growth of
beneficial microorganisms.
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COSTING
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EXPERIMENTATION AND RESULTS

1. Testing Process:

The testing phase is pivotal to our project, designed to rigorously evaluate the performance,
efficiency, and reliability of the semi-automatic fermenter. Our comprehensive testing approach
involves producing two distinct batches of biofertilizers: one using Pseudomonas fluorescence and
the other using Bacillus subtilis. With the industry standard count set at 1 x 10^8 CFU/mL (Colony
Forming Units per milliliter) for both strains, our testing aims to determine the fermenter's ability
to meet and maintain this benchmark.
The microbial count will be calculated using the following formula:

𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐶𝑜𝑙𝑜𝑛𝑖𝑒𝑠 𝐶𝑜𝑢𝑛𝑡𝑒𝑑

Microbial Count (CFU/mL) = { } × Dilution Factor
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑆𝑎𝑚𝑝𝑙𝑒 𝑃𝑙𝑎𝑡𝑒𝑑(𝑚𝐿)
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2. Results :

Microbial Counts:

Pseudomonas fluorescence
Achieved Count: 2 x 10^8 CFU/mL
Industry Standard: 1 x 10^8 CFU/mL
Comparison: Exceeded the industry standard by reaching the target count.

Bacillus subtilis
Achieved Count: 2 x 10^9 CFU/mL
Industry Standard: 1 x 10^8 CFU/mL
Comparison: Surpassed the industry standard with an outstanding count ten times higher.
Implications

The fermenter's performance in achieving and surpassing these microbial counts affirms
its efficiency and effectiveness. These results highlight the fermenter's capability to
consistently produce high-quality biofertilizers, meeting and exceeding industry standards.
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CONCLUSION
The development and successful implementation of the semi-automatic fermenter for
Ecorise Agro-Science Industries mark a pivotal achievement in our project's journey. This
endeavour, rooted in collaborative efforts, innovative design, and rigorous testing, has
enabled us to address a critical need within the agricultural sector: an efficient, reliable,
and cost-effective system for biofertilizer production.
In summary, the semi-automatic fermenter stands as a testament to our dedication,
expertise, and collaborative spirit. It embodies our commitment to delivering innovative
solutions that not only meet but exceed industry standards. With this project's successful
completion, we reaffirm our commitment to excellence and look forward to embarking on
new ventures that will shape the future of agriculture.
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INDIVIDUAL CONTRIBUTION 21

Vishwaraj Patil : Hrishikesh Karpe :

• Final Design • Calculations
• Literature survey • Making the PPT presentation.
• Calculations • Fabrication
• Fabrication • Documentation of Project Diary
• Documentation of Project Report • PPT Preparation
• Documentation of Project Diary
• Project Poster Saurabh Mane :
• Calculations
Abhishek Kasurde : • 3D Model
• Final design • Fabrication
• Calculations • Documentation of Project Diary
• Fabrication • PPT Preparation
• Documentation of Project Report
• Documentation of Project Diary
THANK YOU
Thank you for your attention and interest in our project. Your
support and engagement are greatly appreciated as we continue
to innovate and improve in the field of biofertilizer production.