In pharmaceutical and biotechnology industries, the selection of bioreactors is increasingly influenced by capital efficiency, operational flexibility, and the ability to maintain consistent product quality in shear-sensitive processes. These systems must provide adequate mixing, reliable oxygen transfer ( a), and controlled hydrodynamic environments to support viable cell growth and stable metabolite production.
Introduction:
Orbitally shaken bioreactors (OSRs) are widely used in bioprocessing due to their operational simplicity, low-shear environment, and compatibility with single-use systems across a wide range of working volumes. The absence of mechanical agitation lowers infrastructure and maintenance requirements, while single-use operation reduces cleaning and validation efforts, thereby decreasing both capital expenditure (CAPEX) and operational expenditure (OPEX). In OSRs, orbital motion drives mixing and mass transfer through complex free-surface wave formation, bulk liquid circulation, and continuous gas–liquid interfacial renewal. Reactor performance is strongly influenced by vessel geometry, liquid fill volume, orbital diameter, and shaking frequency, which govern flow behavior, energy input, and gas–liquid interfacial area generation.
This study systematically investigates the hydrodynamic and mass transfer behavior of OSRs under industrially relevant operating conditions. The analysis focuses on the effects of orbital motion on flow topology, shear distribution, and gas–liquid interfacial dynamics. By providing detailed insight into flow and transport phenomena that are difficult to measure experimentally, the study aims to support optimization of reactor design and operating conditions for improved process efficiency, scalability, and operational reliability in bioprocessing applications.