Airlift bioreactor design and manufacturing solutions

At Cultiply, we design and manufacture advanced airlift bioreactors tailored to the demands of modern bioprocessing. Whether you’re cultivating sensitive cell lines or scaling up industrial fermentations, our systems offer precision, reliability and energy efficiency. Think of an airlift bioreactor as the lungs of your process—gentle, yet powerful, circulating life through every drop of culture. Our multidisciplinary team combines expertise in microbiology, bioprocess engineering and industrial design to deliver integrated solutions that optimise mass transfer, reduce shear stress and support sustainable production. Let’s bring your bioprocess vision to life—intelligently, efficiently, and without compromise.

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Design and purchase of custom airlift bioreactors

Cultiply designs each airlift bioreactor as a bespoke system, engineered to meet the biological, operational and economic needs of your process. From lab-scale benchtop units to pilot and industrial reactors, we ensure every component—draft tube, sparger, sensors, control systems—is calibrated for optimal performance.Our collaborative design approach guarantees the right configuration from day one. Once the design is defined, we manufacture and deliver your bioreactor ready for implementation. Tailored design, seamless integration, and long-term reliability—all in one package.

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Key features of our airlift bioreactor systems

Our airlift bioreactors combine simplicity with high-performance engineering. Each system includes a custom draft-tube design to promote circulation without mechanical agitation—minimising shear forces and protecting sensitive cells. Integrated static mixers ensure consistent pH and DO levels, while advanced aeration controls reduce foaming and enhance gas–liquid transfer. Need scalability? We offer flexible volumes and configurations, including external-loop options for enhanced oxygenation. Each unit is compatible with standard sensors and automation systems, ready for GMP compliance and process scale-up. In short: smart design, minimal energy use, and maximum biological performance.

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Applications of airlift bioreactors across industries

Airlift bioreactors are a strong choice for processes that demand gentle yet efficient mixing—across a wide range of sectors. In biopharma and industrial biotechnology, they support microbial fermentation for enzymes, proteins, metabolites, and probiotics, including shear-sensitive organisms such as filamentous fungi and oleaginous yeasts. They’re also ideal for cultivating microalgae. In environmental biotech, airlift systems enable effective wastewater treatment and bioremediation. One versatile platform—adaptable to your medium, organism, and industrial goals.

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Why choose Cultiply for your airlift bioreactor project

At Cultiply, we don’t just build bioreactors—we engineer intelligent fermentation environments. Our team blends microbiology, process engineering, industrial design and manufacturing expertise to create systems that adapt to your process—not the other way around. We customise every detail: fluid dynamics, sensor integration, oxygen transfer, scalability. The result? A bioreactor that works in harmony with your culture, medium and production targets. Whether you’re scaling up a novel strain or optimising a proven process, we provide support from concept to commissioning. Trust Cultiply to turn biological potential into reliable biotechnological performance.

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Frequently asked questions about airlift bioreactor design

 Airlift bioreactors rely on air or gas injection to circulate the liquid phase, without mechanical agitation. This eliminates moving parts, reducing energy consumption and shear stress—making them ideal for sensitive cultures. While stirred tanks offer intense mixing, airlift systems provide gentler, more uniform conditions. Think of it as the difference between a turbulent blender and a carefully flowing stream. The result? Improved cell viability, lower foam production, and easier cleaning—especially beneficial in long-duration or delicate bioprocesses.

If you’re cultivating shear-sensitive microbial systems—such as filamentous fungi, flocculating or oleaginous yeasts, and certain bacteria—an airlift bioreactor can be an excellent option. These designs minimize mechanical stress while maintaining oxygen transfer and reliable circulation, often improving scalability and energy efficiency versus mechanically agitated tanks. Not sure if it’s the right fit? At Cultiply, we’ll assess oxygen demand, broth rheology/viscosity, and cell fragility to recommend the most suitable configuration.

 Absolutely. One of the strengths of airlift systems is their scalability. Thanks to predictable hydrodynamics and a modular design, performance metrics such as gas holdup, circulation velocity and kLa can be translated across scales—from 1 litre to several thousand litres. At Cultiply, we use advanced modelling and pilot testing to ensure seamless scale-up, preserving your process parameters and product quality. Whether you’re moving from benchtop R&D to pilot production or industrial scale, we’ll guide each step.

Oxygen is transferred via gas bubbles introduced at the base of the bioreactor, typically through a sparger. As bubbles rise through the riser tube, they create circulation and promote gas–liquid exchange. The difference in density between gas-rich and gas-poor zones drives the flow. By adjusting bubble size, gas flow rate and the reactor’s geometry, we optimise the oxygen transfer rate (kLa). With no impellers to shear cells or generate heat, oxygen is delivered gently but effectively.

Key design parameters include the height-to-diameter ratio (often between 6:1 and 10:1), the ratio between riser and downcomer areas, and superficial gas velocity (Ug). Internal features like draft tubes, static mixers and gas–liquid separators enhance control. At Cultiply, we calculate these values based on your specific culture, process goals and operational constraints. Whether you prioritise oxygen transfer, low shear, or energy efficiency, our design is engineered to deliver the best balance.

Yes—customisation is at the heart of what we do. We design every airlift bioreactor from the ground up to suit your process: cell type, working volume, oxygen demand, viscosity, medium composition, and more. From sparger design and material selection to sensor integration and automation level, every element is tailored. Whether you need a compact benchtop unit or a full-scale industrial system, we align the equipment with your biological and operational needs—for consistent, scalable results.

We approach low-shear design from multiple angles: careful control of bubble size, use of static mixers instead of impellers, and strategic placement of air inlets. Our geometries promote smooth, laminar circulation—ideal for delicate cells. We also minimise turbulence at gas entry points and reduce bubble collisions that can rupture cell membranes. The result is a calm, oxygen-rich environment where even fragile cultures can thrive. For processes where cell viability is mission-critical, this makes all the difference.

Our airlift bioreactors support a wide range of sensors for real-time control: pH, DO, temperature, pressure, foam, optical density and more. We can integrate SCADA systems, programmable logic controllers (PLCs), or connect to your existing automation infrastructure. Whether you need simple feedback control or advanced data logging and remote access, we build systems that evolve with your process. Intelligent fermentation isn’t a buzzword for us—it’s a design philosophy embedded into every Cultiply reactor.

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    “Cultiply S.L. ha recibido una ayuda de la Unión Europea con cargo al Programa Operativo FEDER de Andalucía 2014-2020, financiada como parte de la respuesta de la Unión a la pandemia de COVID-19 (REACT-UE), para compensar el sobrecoste energético de gas natural y/o electricidad a pymes y autónomos especialmente afectados por el incremento de los precios del gas natural y la electricidad provocados por el impacto de la guerra de agresión de Rusia contra Ucrania.”

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