The new Tetra Pak Bioreactor RF enables stable, scalable fermentation with reduced risk, faster start-up and up to 12% lower operational costs, from pilot to full production, according to the company. It follows Tetra Pak’s acquisition of Bioreactors.net in December 2025 and expands the company’s offering for industrial fermentation and new food production.

New food fermentation, where microorganisms such as yeast, bacteria and fungi convert raw materials into valuable food ingredients, is becoming an increasingly important capability for food and ingredient producers. As the industry looks to diversify ingredient sourcing and improve resource efficiency, producers are moving from pilot testing to industrial-scale production. These companies are therefore seeking systems that deliver consistent performance while reducing variability and operational burden.

Tetra Pak Bioreactor RF is a fermentation vessel designed to maintain stable conditions while providing operators with process insight. From pilot validation and first industrial runs through to full-scale production, the system delivers repeatable performance without increasing operational complexity.

“Industrial fermentation succeeds when performance is repeatable, day after day,” says Rafael Barros, director of the new food business stream at Tetra Pak. “This is designed to reduce operational risk and remove complexity, helping operators stay in control.”

The reactor is pre-assembled and factory-tested, enabling faster installation and commissioning, while reducing disruption to production planning. Its integrated platform design removes the need for separate support structures, lowering installation costs and complexity. These features can help reduce investment costs by up to 8% compared with conventional industrial bioreactors, according to Tetra Pak.

At the core of the system is a patented magnetic agitation system that removes the need for mechanical seals, a common source of contamination risk and process instability in conventional designs. Unlike traditional magnetic agitators, which can struggle to maintain power as vessel size increases, Tetra Pak’s patented system is designed to maintain power and oxygen transfer across the full size range. This helps maintain stable process conditions and reduce the risk of batch loss, typically valued at around €1,000 per cubic metre.

Combined with predefined operating strategies and integrated data monitoring, this enables operators to run processes more efficiently and with greater visibility. Available in sizes from 10 to 50,000 litres, all Tetra Pak Bioreactor RF units use the same design platform, control logic and operating philosophy.