What is a bioreactor and why does a winery need one?

A bioreactor represents an advanced, precisely controlled system engineered to optimize the proliferation of microorganisms essential to winemaking. By maintaining ideal conditions for growth, it empowers wineries to efficiently produce high-concentration inocula of premium commercial yeasts and lactic acid bacteria, or rapidly propagate proprietary native yeast populations to commercially viable levels. This innovative technology delivers unparalleled consistency, accelerates production timelines, and enables greater control over fermentation profiles, ultimately enhancing wine quality, stylistic precision, and operational efficiency.

Beyond its core role in producing high-density inocula for primary alcoholic and malolactic fermentations, the bioreactor serves as a versatile on-site production platform, enabling wineries to autonomously generate proprietary mannoproteins for enhanced mouthfeel and stability, custom yeast nutrients tailored to specific vintage requirements, and even biological vineyard amendments for sustainable soil enrichment and vine health. This multifaceted capability transforms the bioreactor into a comprehensive biotechnological asset, delivering greater self-sufficiency, reduced reliance on external inputs, superior wine quality, and meaningful contributions to regenerative viticulture—all from a single, precision-controlled system.

Challenges

How does a bioreactor work?

LEV2050’s patented* bioreactors deliver precise, fully controlled micro-environments that drive rapid microorganism growth through integrated heating, cooling, agitation, and sterile dry-air delivery. This advanced technology ensures exceptional purity, reproducibility, and performance, setting the new benchmark for precision biotechnology in modern winemaking.

Control of Variables

These biorectors control a number of critical variables, including temperature, oxygen concentration, and agitation. These parameters are adjusted according to a PLC controlled process to ensure optimal growth and production.

Agitation and Oxygenation

Agitation and oxygenation are essential to maintain a uniform and controlled distribution of oxygen in the bioreactor. This is achieved through mechanical agitation and controlled oxygen injection.

Automated Monitoring and Control

Bioreactors are equipped with automatic monitoring and control systems that constantly record process conditions and make real-time adjustments. This ensures that the environment remains within the desired range.

Types of bioreactors

There are several types of bioreactors, each designed for specific applications. Below are some of the most common types:

Fermentation bioreactors are primarily used in the production of microorganisms for food and beverages.
Laboratory bioreactors are smaller systems used in research and development. They are ideal for process optimization and small-scale testing. They are often highly configurable and allow for precise control of process conditions.
In-situ autoclavable bioreactors allow for sterilization of the culture medium in situ (in the bioreactor itself). These bioreactors are intended for high-value-added product applications due to the complexity of the final product process. Therefore, in-situ autoclavable bioreactors reduce the risk of contamination.

Advantages of bioreactors

The use of bioreactors offers several significant advantages over traditional growth and production methods. Some of the key advantages are:

Precise Control: Bioreactors allow for precise control of microorganism multiplication conditions, resulting in more traceable, reproducible, high-quality, and efficient production. This allows for the development of higher-quality products.
Scalability: Bioreactor processes can be easily scaled up, allowing for industrial-scale production.
Research and Development: In the field of research, laboratory bioreactors are essential tools for process development and optimization.

Adoption of Advanced Manufacturing Technologies

Redwood Manufacturing invested in state-of-the-art machinery and automation solutions, including:

Robotic Process Automation (RPA): Implemented robots for repetitive tasks to enhance precision and reduce human error.
Industrial IoT Devices: Installed sensors and connected devices to monitor equipment health and production conditions in real-time.

LEV Bioreactors