Kefir grains production—An approach for volume optimization of two-stage bioreactor system

Abstract The main objective of the present study was to design a continuous two-stage bioreactor system for kefir grains production. Based on the experimental data of time-depended kefir grain mass increase and average pH profile during kefir grains batch propagation, parameters of predictive growth and exponential pH models were initially estimated. Afterwards, the non-linear programming (NLP) optimization problem for estimating the optimal volumes of two unequal in series connected continuously stirred tank bioreactors (CSTB) has been developed. The NLP problem is based on criterion of minimal total holding time (MTHT), kefir grain mass balances in CSTB and parameters of the growth and pH models. The results showed that novel kefir grains production plant with two-stage continuous operation, at capacity, q m ,KG,pr  = 3 kg h −1 and conversion, X o,2  = 0.980, would primarily require investment in two CSTB with V 1  = 5.93 m 3 and V 2  = 5.62 m 3 , respectively. Technological and economical authorization for a two-stage continuous bioreactor system was mainly confirmed with a more than five times lower total bioreactor volume compared to one-stage plant.