Lab Scale Disc Stack Separator

Laboratory-scale centrifugation is essential for early-stage process development, formulation studies, quality control testing, and small-volume sample preparation across the pharmaceutical, biotechnology, chemical, food, and environmental sectors. Traditional laboratory centrifuges (bench-top swing-bucket or fixed-angle rotors) are suitable for small volumes (0.1-50 mL) and simple separations but cannot simulate the continuous flow, high-throughput, or solids handling capabilities of industrial disc stack centrifuges. Conversely, pilot-scale centrifuges require larger sample volumes (10-100 L) and are too large for standard laboratory benchtops. Our Lab Scale Disc Stack Separator has been specifically engineered to bridge this gap, providing true disc stack separation capability in a compact, benchtop form factor that processes sample volumes from 0.5 to 20 liters per batch or up to 10 liters per hour in continuous mode. The disc stack design provides the same separation principles as industrial disc stack centrifuges (high G-force, thin-layer sedimentation, continuous solids ejection), enabling direct correlation to production-scale performance using as little as 500 mL of sample. The lab unit is designed for maximum flexibility, with interchangeable disc stacks (for different particle size ranges), adjustable G-force (up to 12,000 x g), variable feed rates (0.1-10 L/hour), and both batch and continuous operation modes. The compact benchtop design (footprint less than 2 square feet) fits on a standard laboratory bench or inside a biosafety cabinet. All product-contact surfaces are manufactured from electro-polished SUS316L stainless steel with surface roughness below 0.4 micrometers Ra, ensuring complete cleanability and compatibility with pharmaceutical, biological, and chemical samples. The system is fully enclosed with HEPA-filtered venting for biosafety and available with optional cooling for temperature-sensitive samples. The lab separator has been validated for a wide range of applications including cell culture clarification (CHO, HEK293, Vero, MDCK), bacterial harvest (E. coli, Lactobacillus), yeast concentration (S. cerevisiae), algal biomass harvesting, nanoparticle classification, protein precipitate recovery, and wastewater solids analysis. For each application, the operating parameters can be optimized on the lab unit and then directly scaled to pilot or production units using validated scale-up protocols (Sigma factor scaling). The control system provides comprehensive monitoring and data logging capabilities, built around a Siemens PLC with a 7-inch color touchscreen HMI. The user interface presents key parameters including bowl speed, feed rate, discharge mode, temperature, and run time. The system supports recipe storage and data export for process development reports. For pharmaceutical applications, the lab separator is available in a cGMP-compliant configuration with 21 CFR Part 11 audit trail.

The disc stack design at the heart of our lab separator is a true miniature of our production disc stack centrifuges, ensuring that scale-up is reliable and predictable. The disc stack consists of precision-engineered conical discs (typically 5-15 discs) manufactured from stainless steel or plastic, with gap spacing optimized for different applications (0.2-1.0 mm). The bowl diameter is 25-75 mm (compared to 200-800 mm for production), but the geometry—disc angle, gap spacing, flow path—is maintained. This geometric similarity is critical for accurate scale-up because separation performance depends on the shape of the flow channels, not just G-force. The lab unit operates at the same bowl speed (up to 12,000 rpm) as production disc stack units, creating the same centrifugal forces. Scale-up from lab to production is based on the Sigma factor (Σ), a measure of the centrifuge's equivalent settling area. For a given process, the required Σ for production is calculated by multiplying the lab Σ by the scale factor (production throughput / lab throughput). Our scale-up protocols have been validated for hundreds of applications with scale factors from 50x to 5,000x, with average performance deviation of less than 10% between lab and production. The lab separator features a unique batch/continuous operation mode. In batch mode, the unit processes a fixed volume (0.5-20 L) and then stops for manual solids removal. This is ideal for small samples where material is limited. In continuous mode, the partial ejection mechanism removes solids automatically every 5-30 minutes, allowing processing of larger volumes (10-100 L). The ejection mechanism uses the same hydraulic principle as production units, enabling accurate prediction of ejection frequency and solids concentration. The lab unit also includes an integrated peristaltic feed pump with flow rates from 0.1-10 L/hour, a feed reservoir (250 mL to 2 L), and separate collection vessels for clarified liquid and solids. Optional cooling jacket maintains sample temperature between 4-40°C, critical for temperature-sensitive biological samples. The entire system is controlled via a touchscreen interface with pre-programmed protocols for common applications. For quality control laboratories, the lab separator can be used for incoming raw material testing (particle size distribution, solids content), in-process control (clarification efficiency, product recovery), and final product testing (residual solids, purity). For research laboratories, the lab separator enables rapid screening of separation conditions (G-force, feed rate, disc stack type) using minimal material, accelerating process development timelines by months.

Our Lab Scale Disc Stack Separator incorporates several advanced features specifically designed for laboratory applications. The feed system includes a variable-speed peristaltic pump and a small feed reservoir (250 mL standard, optional 1-2 L). The control system provides comprehensive monitoring and data logging, built around a Siemens PLC with a 7-inch color touchscreen HMI. The user interface presents key parameters including bowl speed, feed rate, temperature, run time, and ejection count. The system supports recipe storage for different products and data export to USB or network. The combination of compact design and advanced process control makes our lab separator the preferred choice for R&D and QC laboratories worldwide.