Custom-made stainless steel fermenters: development process

Your Custom Stainless Steel Fermenter: 11-Step Development Process – From Concept to Installation

Here's a step-by-step guide to what happens after we receive your order for a custom stainless steel fermenter. You'll see that it's a complete process, spanning from defining your specifications to final approval at your site.

1. Project Team Formation

As soon as we receive your order, we form a dedicated project team. It meets at least once a week throughout the development and detailed design phase of your fermenter.

2. P&ID Validation

The project team's first mission is to finalize and validate the P&ID (Piping and Instrumentation Diagram). This document describes all the flows and instruments in your fermenter. It's a bit like the "road map" that will guide the rest of the project.

3. 2D Design

Once the P&ID has been approved, we begin the detailed 2D design. You will then have the opportunity to review and validate the plans to ensure that each element meets your expectations. Once the plans are signed, we can move on to the next step.

4. 3D Design

The 3D design allows us to precisely visualize the routing of each pipe, detect any blind spots or "dead arms," ​​and, above all, verify that the skid (i.e., the structure that houses all the feeds and connections for your fermenter) will fit seamlessly into your laboratory (and pass through doorways, for example).

5. Documentation and Design Qualification (DQ)

Once the 2D and 3D designs are approved, we produce all the necessary documents, which form the documentation package. This step is called Design Qualification (DQ). Once the DQ is approved, manufacturing can begin.

6. Fermenter Manufacturing

Manufacturing is generally the longest phase of the project. During this period, we stay in regular contact with you to keep you informed of progress and manage any last-minute adjustments.

7. FAT (Factory Acceptance Test)

Once manufacturing is complete, we conduct the FAT (Factory Acceptance Test). This takes place at our factory (at our partner's or our own production site) and involves performing a series of tests to verify that the equipment meets your specifications.

If everything is approved, we can disassemble the fermenter for shipping: by sea (most common) or by air if deadlines are tight and space permits.

8. Sea (or air) Transportation

9. On-site Installation

Upon arrival at your site, we reassemble the fermenter exactly as you saw it during the FAT. 10. SAT (Site Acceptance Test)

We then proceed with the on-site start-up and qualification, also known as the SAT (Site Acceptance Test).

During this qualification, we repeat the same checks as during the FAT to ensure that everything functions as expected under your actual operating conditions.

11. Training and Final Documentation

Once the SAT is validated, we train your teams in the use and maintenance of the equipment. Finally, we jointly sign all official documents certifying that your fermenter meets your specifications and is ready for use.

Typical Timeframes

This entire process can take between 4 and 7 months, depending on:

The time required to validate the design (2D/3D).

Manufacturing time.

Sea freight (generally 8 to 10 weeks).

If you are in a hurry and the equipment allows it, air freight can be considered, but it is often more expensive.

There you have it, you know everything!

As you can see, designing and building a custom stainless steel fermenter is a detailed process that requires effective communication and validation at every step to avoid any unpleasant surprises.