Software sensors for fermentation processes

Four software sensors based on standard on-line data from fermentation processes and simple mathematical models were used to monitor a number of state variables in Escherichia coli fed-batch processes: the biomass concentration, the specific growth rate, the oxygen transfer capacity of the bioreactor, and the new R _O/S sensor which is the ratio between oxygen and energy substrate consumption. The R _O/S variable grows continuously in a fed-batch culture with constant glucose feed, which reflects the increasing maintenance demand at declining specific growth rate. The R _O/S sensor also responded to rapid pH shift-downs reflecting the increasing demand for maintenance energy. It is suggested that this sensor may be used to monitor the extent of physiological stress that demands energy for survival.     

Heat production by ruminal bacteria in continuous culture and its relationship to maintenance energy.

Selenomonas ruminantium HD4 and Bacteroides ruminicola B(1)4 were grown in continuous culture with glucose as the energy source, and heat production was measured continuously with a microcalorimeter. Because the bacteria were grown under steady-state conditions, it was possible to calculate complete energy balances for substrate utilization and product formation (cells, fermentation acids, and heat). As the dilution rate increased from 0.04 to 0.60 per h, the heat of fermentation declined from 19 to 2% and from 34 to 8% for S. ruminantium and B. ruminicola, respectively. At slow dilution rates the specific rate of heat production remained relatively constant (135 mW/g [dry weight] or 190 mW/g of protein for S. ruminantium and 247 mW/g [dry weight] or 467 mW/g of protein for B. ruminicola). Since the heat due to growth-related functions was small compared to maintenance expenditures, total heat production provided a reasonable estimate of maintenance under glucose-limiting conditions. As the dilution rate was increased, glucose eventually accumulated in the chemostat vessel and the specific rates of heat production increased more than twofold. Pulses of glucose added to glucose-limited cultures (0.167 per h) caused an immediate doubling of heat production and little increase in cell protein. These experiments indicate that bacterial maintenance energy is not necessarily a constant and that energy source accumulation was associated with an increase in heat production.     

Microcalorimetric investigations of the metabolism of yeasts VII. Flow-calorimetry of aerobic batch cultures

Summary The heat evolution of aerobic batch cultures of growing yeast (Saccharomyces cerevisiae) in glucose media was investigated by a combination of a flow-microcalorimeter with a fermentor vessel. The course of heat production, cell production and the rate of oxygen consumption were qualitatively the same for all glucose concentrations between 10 mM and 100 mM. Under optimal aerobic conditions a triphasic growth was observed due to the fermentation of glucose to ethanol, respiration of ethanol to CO₂ and acetate, and respiration of acetate to C0₂. Energy and carbon were found to be in balance for all glucose concentrations.     

Experimental bioenergetics ofSaccharomyces cerevisiae in respiration and fermentation

Aerobic growth of Saccharomyces cerevisiae on glucose was investigated, focusing on the heat evolution as it relates to biomass and ethanol synthesis. “Aerobic fermentation” and “aerobic respiration” were established respectively in the experimental system by performing batch and fed-batch experiments. “Balanced growth” batch cultivations were carried out with initial sugar concentrations ranging from 10 to 70 g/L, resulting in different degrees of catabolite repression. The fermentative heat generation was continuously monitored in addition to the key culture parameters such as ethanol production rate, CO₂ evolution rate, O₂ uptake rate, specific growth rate, and sugar consumption rate. The respective variations of the above quantities reflecting the variations in the catabolic activity of the culture were studied. This was done in order to evaluate the microbial regulatory system, the energetics of microbial growth including the rate of heat evolution and the distribution of organic substrate between respiration and fermentation. This study was supported by closing C, energy, and electron balances on the system. The comparison of the fractions of substrate energy evolved as heat (δ_h) with the fraction of available electrons transferred to oxygen (?_O2) indicated equal values of the two (0.46) in the aerobic respiration (fed-batch cultivation). However, the glucose effect in batch cultivations resulted in smaller ?_O2 than δ_h, while both values decreased in their absolute values. The evaluation of the heat energetic yield coefficients, together with the fraction of the available electrons transferred to O, contributed to the estimation of the extent of heat production through oxidative phosphorylation.     

Monitoring growth and acetic acid secretion by a thermotolerantBacillus using conduction microcalorimetry

Summary A method is described to determine power of heat-time curves by conduction microcalorimetry in order to monitor the viability and ability of a thermotolerantBacillus strain to secrete acetic acid both during exponential growth and during stationary-phase. In this system secreted acetic acid is neutralized by an insoluble source of lime (dolime) which results in a poor correlation between optical density and culture dry weight. As an alternative, cells and residual dolime were rapidly resuspended in isothermal fresh medium with glucose in a conduction microcalorimeter. Heat evolution was rapid over a period of 200–800 s. Steady state heat evolution rate decreased as a function of culture time and did not correlate with: 1) specific growth rate: 2) viable cell number: 3) glucose consumption rate; or 4) acetic acid secretion rate. Glucose consumption and acetic acid secretion during the stationary growth phase were correlated with specific heat evolution rate. These initial results indicate that this technique may be useful for further development as an on-line flow or stopped-flow method to monitor the physiology of bacilli in response to nutrient depletion or growth inhibition.     

Estimating the maintenance energy and biomass concentration of Saccharomyces cerevisiae by continuous calorimetry

Continuous calorimetry has been applied to monitoring the heat evolution of Saccharomyces cerevisiae grown on d-glucose. The heat evolution, together with the energy and carbon balances, was used to evaluate the energetic efficiency of biomass, by-product biosynthesis, fermentative heat evolution as well as the maintenance energy of S. cerevisiae in ‘aerobic fermentation’ and ‘aerobic respiration’. In aerobic fermentation, under catabolite repression, the fraction of substrate energy converted to heat evolution, maintenance requirement, and biomass decreased with the increase of d-glucose concentration. The fraction of substrate energy converted to ethanol is the highest value and it could contribute up to 70% of the total substrate energy. In aerobic respiration, 43% of the total substrate energy was evolved as heat. While 50% of the total substrate energy was converted into biomass, only 7% of the total substrate energy was used for maintenance functions. The maintenance energy coefficient of S. cerevisiae was determined to be 0.427 MJ kg^?1 cell h^?1 (0.102 kcal g^?1 cell h^?1). For the first time, heat evolution together with yield-maintenance energy was used to predict biomass concentration during the fed-batch cultivation of S. cerevisiae.     

Continuous Fermentation of Novobiocin

Continuous fermentation trials with Streptomyces niveus in a nine-stage fermentation system (7-liter reaction volume per stage) indicated that the cultures used gradually lost their ability to produce novobiocin when cultured over periods from 10 to 25 days. It was found that mycelial degeneration could be circumvented by operational means during continuous culture using the following technique: Two interchangeable 24-liter stages were installed at the front end of the nine-stage system and connected in parallel with the latter. Alternatingly one of these two tanks was then used as first stage of the continuous fermentation system. The holdup time in the first vessel was adjusted to limit cell growth chiefly to this stage so that most of the antibiotic production took place in subsequent stages. The first stages were switched at approximately weekly intervals. Each of the new tanks was prepared as a batch, inoculated with a high-producing cell population, and allowed to grow for 3 days before it was connected to the remaining system for continuous operation. Using this technique no evidence of culture degeneration was encountered in subsequent novobiocin production stages over a period of 33 days. In conventional runs without periodic replacement of the first stage, culture degeneration with the novobiocin fermentation occurred within a period of 10 to 25 days of continuous operation. This observation indicates that the described technique offers a solution to the problem of maintaining high steady-state titers in continuous novobiocin fermentations. Extension of this technique to other continuous fermentations where culture degeneration is a problem is indicated.     

温度对丙酮酸生物合成动力学、能荷和氧化-还原度的影响

在光滑球拟酵母(Torulopsis glabrata620)生产丙酮酸的过程中,温度对丙酮酸生物合成有着重要的影响。考察了不同发酵温度下基质消耗、细胞生长、丙酮酸合成及能荷水平和氧化-还原度等方面的差异。在恒温发酵中,维持较高的发酵温度可以增强糖耗,促进菌体生长,加速丙酮酸积累,但前期胞内能荷水平较高,菌体消耗较多葡萄糖合成菌体,后续产酸能力不足,导致丙酮酸得率降低;维持较低的发酵温度可以在发酵后期提供稳定的产酸能力,但菌体代谢缓慢,后期胞内NADH/NAD 水平较高,丙酮酸生产强度降低。因此仅仅采取单一的温度控制策略很难达到丙酮酸高产量、高产率和高生产强度的统一。     

High temperature stimulates acetic acid accumulation and enhances the growth inhibition and ethanol production by Saccharomyces cerevisiae under fermenting conditions

Cellular responses of Saccharomyces cerevisiae to high temperatures of up to 42 °C during ethanol fermentation at a high glucose concentration (i.e., 100 g/L) were investigated. Increased temperature correlated with stimulated glucose uptake to produce not only the thermal protectant glycerol but also ethanol and acetic acid. Carbon flux into the tricarboxylic acid (TCA) cycle correlated positively with cultivation temperature. These results indicate that the increased demand for energy (in the form of ATP), most likely caused by multiple stressors, including heat, acetic acid, and ethanol, was matched by both the fermentation and respiration pathways. Notably, acetic acid production was substantially stimulated compared to that of other metabolites during growth at increased temperature. The acetic acid produced in addition to ethanol seemed to subsequently result in adverse effects, leading to increased production of reactive oxygen species. This, in turn, appeared to cause the specific growth rate, and glucose uptake rate reduced leading to a decrease of the specific ethanol production rate far before glucose depletion. These results suggest that adverse effects from heat, acetic acid, ethanol, and oxidative stressors are synergistic, resulting in a decrease of the specific growth rate and ethanol production rate and, hence, are major determinants of cell stability and ethanol fermentation performance of S. cerevisiae at high temperatures. The results are discussed in the context of possible applications.     

Measurement of heat evolution and correlation with oxygen consumption during microbial growth

A procedure for measuring the rate of heat production from a fermentation has been developed. The method is based on measuring the rate of temperature rise of the fermentation broth resulting from metabolism, when the temperature controller is turned off. The heat accumulation measured in this manner is then corrected for heat losses and gains. A sensitive thermistor is used to follow the temperature rise with time. This procedure is shown to be as accurate as previous methods but much simpler in execution. Using this technique, the rate of heat production during metabolism was found to correlate with the rate of oxygen consumption. Experiments were performed using bacteria (E. coli and B. subtilis), a yeast (C. intermedia), and a mold (A. niger). The substrates investigated included glucose, molasses, and soy bean meal. The proportionality constant for the correlation is independent of the growth rate, slightly dependent on the substrate, and possibly dependent On the type of organism growth. This correlation has considerable potential for predicting heat evolution from the metabolism of microorganisms on simple or complex substrates and providing quantitative parameters necessary for heat removal calculations.     

Fructose production from sucrose and high fructose syrup: A mycelial fungal system

Summary The use of Mucor sp. M105 and Fusarium sp. F5 in the production of fructose from sugarcane sucrose and high fructose syrup (HFS) was investigated. Although Mucor sp. could not utilize sucrose as the sole carbon and energy source for cell growth, Mucor sp. preferentially utilized glucose in a glucose:fructose (1:1) mixture during fermentation to ethanol. In contrast, Fusarium sp. utilized sucrose as sole carbon source by secretion of extracellular hydrolytic enzymes that degraded the disaccharide. In Fusarium sp., glucose formation in the medium was faster than fructose. Due to the low consumption rate of fructose, this substrate remained in the fermentation broth. The application of these biological systems for the production of fructose from either sucrose or HFS is discussed.     

Control of the selectivity of butyric acid production and improvement of fermentation performance withClostridium tyrobutyricum

Summary The parameters that control fermentation performance of butyrate production have been studied with a selected strain ofClostridium tyrobutyricum. Fed-batch supply of glucose increased productivity for butyrate. The ratio of butyrate to total acids was strongly influenced by the growth rate of the bacteria, acetate being produced along with butyrate at higher growth rates. In glucose-limited, fed-batch cultures, initially produced acetate was re-utilized, resulting in exclusive production of butyrate. In cultures with non-limiting glucose feeding, the butyrate concentration reached 42.5 g·1^–1 with a selectivity of 0.90, a productivity of 0.82 g·^–1 per hour and a yield of 0.36 g·g^–1 The effects of the mode of supply of glucose on the production of butyrate and acetate are discussed in relation with the energy requirements for cell growth.     

A re-assessment of bacterial growth efficiency: the heat production and membrane potential of Streptococcus bovis in batch and continuous culture

Glucose-limited, continuous cultures (dilution rate 0.1 h^-1) of Streptococcus bovis JB1 fermented glucose at a rate of 3.9 mol mg protein^-1 h^-1 and produced acctate, formate and ethanol. Based on a maximum ATP yield of 32 cells/mol ATP (Stouthamer 1973) and 3 ATP/glucose, the theoretical glucose consumption for growth would have been 2.1 mol mg protein^-1 h^-1. Because the maintenance energy requirement was 1.7 mol/mg protein/h (Russell and Baldwin 1979), virtually all of the glucose consumption could be explained by growth and maintenance and the Y_ATP was 30. Glucose-limited, continuous cultures produced heat at a rate of 0.29 mW/mg protein, and this value was similar to the enthalpy change of the fermentation (0.32 mW/mg protein). Batch cultures (specific growth rate 2.0 h^-1) fermented glucose at a rate of 81 mol mg protein^-1 h^-1, and produced only lactate. The heat production was in close agreement with the theoretical enthalpy change (1.72 versus 1.70 mW/mg protein), but only 80% of the glucose consumption could be accounted by growth and maintenance. The Y_ATP of the batch cultures was 25. Nitrogen-limited, glucose-excess, non-growing cultures fermented glucose at a rate of 6.9 mol mg protein^-1 h^-1, and virtually all of the enthalpy for this homolactic fermentation could be accounted as heat (0.17 mW/mg protein). The nitrogenlimited cultures had a membrane potential of 150 mV, and nearly all of the heat production could be explained by a futile cycle of protons through the cell membrane (watts = amperes x voltage where H⁺/ATP was 3). The membrane voltage of the nitrogen-limited cells was higher than the glucose-limited continuous cultures (150 versus 80 mV), and this difference in voltage explained why nitrogen-limited cultures consumed glucose faster than the maintenance rate. Batch cultures had a membrane potential of 100 mV, and this voltage could not account for increased glucose consumption (more than growth plus maintenance). It appears that another mechanism causes the increased heat production and lower growth efficiency of batch cultures.     

Effect of medium osmolarity on the bioproduction of glycerol and ethanol by Hansenula anomala growing on glucose and ammonium

The osmotolerant yeast Hansenula anomala survives in media at low water activity resulting from increasing NaCl concentrations in the culture medium by producing compatible solutes. High salinity resulted in the use of a large part of the assimilated carbon substrate (glucose) for cell maintenance (28%), required for intracellular synthesis compounds and for osmotic cell regulation. The maintenance coefficient for non-growth-associated glucose consumption was found to be 0.38 mmol glucose g biomass⁻¹ h⁻¹. For decreasing water activity, there is a competition between the pathways leading to glycerol and ethanol production, until an experimental ethanol/total glycerol ratio reached a value 3.4 for 2 mol l⁻¹ NaCl (close to the theoretical value of 4)—illustrating the osmodependent channelling of carbon towards polyols production. This competition leads to a cessation of ethanol production during the stationary state before that of glycerol. Since osmotic adjustment occurred mainly during growth, glycerol production during stationary state can be clearly related to another mechanism other than osmotic: it was excreted by a fermentative mechanism to ensure energy for cell maintenance.     

Modeling of glycerol production by fermentation in different reactor states

A kinetic model of glycerol production by fermentation with the osmophilic yeast Candida krusei was studied firstly by analogies to published works. Considering that the glycerol produced competes with glucose, as a second carbon source for energy maintenance, mathematical models of glucose utilization and glycerol accumulation were modified further. By adjusting only two variable macrokinetic parameters, K_S and β, the model simulations could fit experimental data well when the reactor was changed from Airlift Loop Reactor in different scale or airlift mode to Stirred Vessel. To avoid a significant reduction in glycerol production in the latter fermentation stage, the final condition of the fermentation, determined by the concentration ratio of glycerol to glucose, was also investigated in four different Reactor States. The kinetic models and simulation results can provide certain reference for scale up of glycerol production by fermentation.     

Production of <Emphasis Type="SmallCaps">l</Emphasis>-alanine by metabolically engineered <Emphasis Type="Italic">Escherichia coli</Emphasis>

Escherichia coli W was genetically engineered to produce l-alanine as the primary fermentation product from sugars by replacing the native d-lactate dehydrogenase of E. coli SZ194 with alanine dehydrogenase from Geobacillus stearothermophilus. As a result, the heterologous alanine dehydrogenase gene was integrated under the regulation of the native d-lactate dehydrogenase (ldhA) promoter. This homologous promoter is growth-regulated and provides high levels of expression during anaerobic fermentation. Strain XZ111 accumulated alanine as the primary product during glucose fermentation. The methylglyoxal synthase gene (mgsA) was deleted to eliminate low levels of lactate and improve growth, and the catabolic alanine racemase gene (dadX) was deleted to minimize conversion of l-alanine to d-alanine. In these strains, reduced nicotinamide adenine dinucleotide oxidation during alanine biosynthesis is obligately linked to adenosine triphosphate production and cell growth. This linkage provided a basis for metabolic evolution where selection for improvements in growth coselected for increased glycolytic flux and alanine production. The resulting strain, XZ132, produced 1,279 mmol alanine from 120 g l⁻¹ glucose within 48 h during batch fermentation in the mineral salts medium. The alanine yield was 95% on a weight basis (g g⁻¹ glucose) with a chiral purity greater than 99.5% l-alanine. Electronic supplementary material The online version of this article (doi:) contains supplementary material, which is available to authorized users.     

Regulation of carbon and electron flow in Propionispira arboris: physiological function of hydrogenase and its role in homopropionate formation

Abstract Hydrogenase activity was characterized in cell extracts of Propionispira arboris that consumed or produced H₂, coupled to methyl viologen reduction, and displayed highest levels (2.6 μmol/min/mg protein) in extracts prepared from fumarate-grown cells. Reversible hydrogenase activity in cell extracts correlated with the production of low levels of hydrogen during the growth phase and its subsequent consumption during the stationary phase of cells grown on glucose or lactate as the carbon and energy source. The addition of exogenous hydrogen to glucose, lactate or fumarate-grown cells dramatically increased propionate production at the expense of acetate formation. This accounted for the formation of propionate as nearly the sole end product of glucose fermentation under two atmospheres of hydrogen. The physiological function of hydrogenase in regulation of carbon and electron flow, and the significance of the results in applied and environmental microbiology are discussed.     

Phenazine redox cycling enhances anaerobic survival in Pseudomonas aeruginosa by facilitating generation of ATP and a proton‐motive force

While many studies have explored the growth of Pseudomonas aeruginosa, comparatively few have focused on its survival. Previously, we reported that endogenous phenazines support the anaerobic survival of P. aeruginosa, yet the physiological mechanism underpinning survival was unknown. Here, we demonstrate that phenazine redox cycling enables P. aeruginosa to oxidize glucose and pyruvate into acetate, which promotes survival by coupling acetate and ATP synthesis through the activity of acetate kinase. By measuring intracellular NAD(H) and ATP concentrations, we show that survival is correlated with ATP synthesis, which is tightly coupled to redox homeostasis during pyruvate fermentation but not during arginine fermentation. We also show that ATP hydrolysis is required to generate a proton‐motive force using the ATP synthase complex during fermentation. Together, our results suggest that phenazines enable maintenance of the proton‐motive force by promoting redox homeostasis and ATP synthesis. This work demonstrates the more general principle that extracellular redox‐active molecules, such as phenazines, can broaden the metabolic versatility of microorganisms by facilitating energy generation.     

Physiological and fermentation properties of <Emphasis Type="Italic">Bacillus coagulans</Emphasis> and a mutant lacking fermentative lactate dehydrogenase activity

Bacillus coagulans, a sporogenic lactic acid bacterium, grows optimally at 50–55°C and produces lactic acid as the primary fermentation product from both hexoses and pentoses. The amount of fungal cellulases required for simultaneous saccharification and fermentation (SSF) at 55°C was previously reported to be three to four times lower than for SSF at the optimum growth temperature for Saccharomyces cerevisiae of 35°C. An ethanologenic B. coagulans is expected to lower the cellulase loading and production cost of cellulosic ethanol due to SSF at 55°C. As a first step towards developing B. coagulans as an ethanologenic microbial biocatalyst, activity of the primary fermentation enzyme L-lactate dehydrogenase was removed by mutation (strain Suy27). Strain Suy27 produced ethanol as the main fermentation product from glucose during growth at pH 7.0 (0.33 g ethanol per g glucose fermented). Pyruvate dehydrogenase (PDH) and alcohol dehydrogenase (ADH) acting in series contributed to about 55% of the ethanol produced by this mutant while pyruvate formate lyase and ADH were responsible for the remainder. Due to the absence of PDH activity in B. coagulans during fermentative growth at pH 5.0, the l-ldh mutant failed to grow anaerobically at pH 5.0. Strain Suy27-13, a derivative of the l-ldh mutant strain Suy27, that produced PDH activity during anaerobic growth at pH 5.0 grew at this pH and also produced ethanol as the fermentation product (0.39 g per g glucose). These results show that construction of an ethanologenic B. coagulans requires optimal expression of PDH activity in addition to the removal of the LDH activity to support growth and ethanol production.