Performance of a Pharmaceutical Single-Use Stirred Tank Operating at Different Filling Volumes: Mixing Time, Fluid Dynamics and Power Consumption

Single-use bioreactors (SUBs) are revolutionizing biotechnology and biopharmaceutical manufacturing by offering cost-efficient, flexible, and scalable alternatives to traditional reusable systems. These bioreactors, made from disposable and pre-sterilized materials, streamline cell cultivation for biological production while minimizing the need for complex cleaning and sterilization. A critical aspect of SUB performance lies in optimizing hydrodynamic parameters flow field, power consumption, mixing time, and energy efficiency, which directly influence process outcomes. This study investigates the hydrodynamic performance of an SUB system through stereo Particle Image Velocimetry (PIV) to analyze flow fields, Planar Laser-Induced Fluorescence (PLIF) for mixing time, and Electro Resistance Tomography (ERT) for further insights into mixing dynamics. The results, evaluated at varying impeller speeds and fill heights, provide a comprehensive understanding of flow behavior, mixing efficiency, and power requirements. This work highlights the importance of hydrodynamic characterization in optimizing SUB design and operation, contributing to more sustainable and efficient biopharmaceutical production.