Cephalosporin C production by immobilized Cephalosporium acremonium cells in a repeated batch tower bioreactor

The industrial production of antibiotics with filamentous fungi is usually carried out in conventional aerated and agitated tank fermentors. Highly viscous non-Newtonian broths are produced and a compromise must be found between convenient shear stress and adequate oxygen transfer. In this work, cephalosporin C production by bioparticles of immobilized cells of Cephalosporium acremonium ATCC 48272 was studied in a repeated batch tower bioreactor as an alternative to the conventional process. Also, gas-liquid oxygen transfer volumetric coefficients, k(L)a, were determined at various air flow-rates and alumina contents in the bioparticle. The bioparticles were composed of calcium alginate (2.0% w/w), alumina ( < 44 micra), cells, and water. A model describing the cell growth, cephalosporin C production, oxygen, glucose, and sucrose consumption was proposed. To describe the radial variation of oxygen concentration within the pellet, the reaction-diffusion model forecasting a dead core bioparticle was adopted. The k(L)a measurements with gel beads prepared with 0.0, 1.0, 1.5, and 2.0% alumina showed that a higher k(L)a value is attained with 1.5 and 2.0%. An expression relating this coefficient to particle density, liquid density, and air velocity was obtained and further utilized in the simulation of the proposed model. Batch, followed by repeated batch experiments, were accomplished by draining the spent medium, washing with saline solution, and pouring fresh medium into the bioreactor. Results showed that glucose is consumed very quickly, within 24 h, followed by sucrose consumption and cephalosporin C production. Higher productivities were attained during the second batch, as cell concentration was already high, resulting in rapid glucose consumption and an early derepression of cephalosporin C synthesizing enzymes. The model incorporated this improvement predicting higher cephalosporin C productivity.     

Effects of solid-phase mass transfer on the performance of a stirred anaerobic sequencing batch reactor containing immobilized biomass

This work reports on experiments for an anaerobic sequencing batch reactor containing immobilized biomass which aimed at verifying the effects of solid-phase mass transfer on the reactor's overall performance. Four experiments were carried out at 30 degrees C with cubic polyurethane foam particles previously inoculated with anaerobic biomass. Different solid-phase mass transfer conditions were reached in each experiment by varying the size of the bioparticle from 0.5 to 3.0 cm. The reactor was fed with a low-strength synthetic wastewater containing protein, carbohydrates and lipid and the effects of mass transfer were evaluated through dynamic substrate concentration profiles during 8-hour batch cycles. A modified first-order kinetic model provided a good representation of the behavior of the dynamic concentration profiles. The solid-phase mass transfer was found to slightly affect the concentration of effluent organic matter expressed as chemical oxygen demand (COD). The concentration of residual effluent substrate increased as the size of the bioparticle was increased. The cycle time was not affected as the size of the bioparticle was increased from 0.5 to 2.0 cm. However, it was found that the cycle time in a reactor with 3.0-cm cubic particles should be higher than that required in systems with smaller particles. The apparent first-order kinetic parameter was estimated as 0.59+/-0.01 h(-1) for experiments with bioparticle sizes ranging from 0.5 to 2.0 cm, while a value of 0.48 h(-1) was obtained in the experiment with 3.0-cm bioparticles.     

胞外青霉素酰化酶产生菌的选育

利用纸片显色方法,从土壤甲诀速筛选出98株产胞外青霉素酰化酶的菌种,经复筛其中10株酶活力较高,经鉴定均属于巨大芽孢杆菌。经单株分离得46号菌,用这株菌进行了产酶条件的研究,在最适产酶条件下,酶话力比开始提高了3．6倍。在此基础上又进行了物理化学因素处理,得突变株UL-81,酶活力达720u／1 Ooml发酵液。对原株和突变株进行比较,发现UL-81菌落、细胞形态、诱导剂苯乙酸用量及添加时间等明显不同于原株。在500L罐发酵酶活达8 20u／1OOml发酵液,为开始酶活的16倍。     

High cell density culture of a recombinant Escherichia coli producing penicillin acylase in a membrane cell recycle fermentor

A recombinant Escherichia coli HB101(pPAKS2) producing penicillin acylase was cultured in a membrane cell recycle fermentor. The strain was very stable throughout the whole experiment. The main inhibitory by-product was acetic acid, and cell growth ceased when its concentration was above 14 g/L Cell density could be increased up to 145 g/L dry weight without experiencing by-product inhibition by regulating glucose concentration in the fermentor and by using total membrane recycle. Acetic acid formation was negligible not only when cells were cultured in medium containing no glucose but also when glucose was limited. Dissolved oxygen control as well as glucose limitation was an indispensable condition for minimizing acetic acid formation when the medium contained glucose. Low concentrations of accumulated acetic acid were reused when glucose was limited. Use of highly concentrated medium reduced the membrane surface area required for cell recycle greatly. The recycle fermentor could be operated in various operational modes including partial bleed and repeated recycle culture to give high productivity. Productivity of a repeated recycle system was over 10 times higher than that of a simple batch system.     

Analysis of a continuous, aerobic, fixed-film bioreactor. I. Steady-state behavior

The analysis of a continuous, aerobic, fixed-film bioreactor is performed by simulating the behavior of penicillin production in a three-phase fluidized bed. Rigorous mathematical models are developed for a fluidized-bed fermentor in which bioparticles are fluidized by the liquid medium and air. The steady-state performance of the fluidized-bed reactor is appraised in terms of penicillin productivity and outlet concentration by considering the two extremes in contacting patterns, complete back-mix and plug flow, in the absence of a growing biofilm. The results show that the complete back-mix contacting pattern is preferred over that of plug flow due to the nature of the penicillin kinetic relationships. It is also shown that for the dual-nutrient (glucose and oxygen) penicillin reaction system the optimum biofilm thickness does not equal the penetration depth of a limiting nutrient, but depends upon the total reactor configuration.     

Analysis of a continuous, aerobic, fixed-film bioreactor. II. Dynamic behavior

The dynamic analysis of a continuous, aerobic, fixed-film bioreactor has been performed. Rigorous mathematical models have been developed for a fluidized-bed fermentor with biofilm growth. The transient performance of the reactor is appraised in terms of outlet penicillin concentration for constant, as well as variable carbon substrate feed rates. The effect of the reactor oxygen transfer capacity is elucidated for those cases employing substrate feeding strategies. The results show that penicillin production in a continuous, fixed-film bioreactor reaches a maximum with processing time, but subsequently decreases as cell mass accumulates and substrate deficiencies occur. The maximum production level can be maintained for increased operating times if the substrate supply is continuously increased. The duration of this prolonged production is a direct function of the rate of increase and the operating time at which the increase is initiated. The oxygen transfer capacity of the reactor was found to be important to the effectiveness of a feeding strategy.     

Resistance of bioparticles formed of phosphate-accumulating bacteria and zeolite to harsh environmental conditions

Extreme environmental conditions, such as pH fluctuations, high concentrations of toxicants or grazing of protozoa, can potentially be found in wastewater treatment systems. This study was carried out to provide specific evidence on how ‘bioparticles’ can resist these conditions. The term ‘bioparticle’ is used to describe a particle comprising natural zeolitized tuff with a developed biofilm of the phosphate-accumulating bacterial species, Acinetobacter junii, on the surface. The bacteria in the biofilm were protected from the negative influence of extremely low pH, high concentrations of benzalkonium-chloride and grazing by Paramecium caudatum and Euplotes affinis, even under conditions that caused complete eradication of planktonic bacteria. During an incubation of 24?h, the biofilms were maintained and bacteria detached from the bioparticles, thus bioaugmenting the wastewater. The bioparticles provided a safe environment for the survival of bacteria in harsh environmental conditions and could be used for successful bioaugmentation in wastewater treatment plants.     

Hyper production of enzyme penicillin amidase by locally isolated thermo-tolerantBacillus sp. MARC-0103 from rice starch in cheese whey

The present study concern with the extracellular production of penicillin amidase in a cost-effective cheese whey medium under submerged fermentation. ABacillus sp. MARC-0103 producing a high level of extra cellular penicillin G amidase was isolated from rice starch by heat shock method. The penicillin G amidase production in the strain was induced by phenyl acetic acid. The culture medium was optimized by using Plackett-Burman and central composite experimental designs for enhanced production of penicillin amidase. The factorial design indicated that the main factors that positively affect penicillin amidase production were casein hydro-lysate, CaCl2·2H2O, FeCI3·6H2O, Na2SO4 and cheese whey, whereas the presence of calcium carbonate and magnesium chloride in the medium had no effect on enzyme production. Phenyl acetic acid concentration and time of addition was found critical for enzyme pro duction. Enzyme production was enhanced very much by multiple addition of inducer. Other cultural condition such as pH, temperature, inoculum size and age were also optimized. More than two fold increase in enzyme production (40.7 U/ml/min) was observed under optimized cultural conditions. The molecular mass was estimated to be 40.0 kDa by SDS-PAGE.     

Studies on cephalosporin-C production in an air lift reactor using different growth modes of Cephalosporium acremonium

This paper deals with the studies on Cephalosporin-C production in a lab-scale airlift reactor using Cephalosporium acremonium. Various growth modes, viz. pellets and Siran supported bioparticles were used to improve the process over conventional free mycelial fermentation. Cephalosporin-C production was significantly improved by using bioparticles over the free mycelial culture, probably due to the enhanced mass transfer in the fermentation broth. However, the biofilm of the bioparticles became unstable as the fermentation proceeded, and increase in the free cells in the broth occurs. The maximum specific growth rate of free cells, pellets and Siran carrier were observed to be 0·037, 0·033 and 0·045 h⁻¹, respectively. The oxygen transfer coefficient also improved for the immobilised modes (100 h⁻¹, 70 h⁻¹ for Siran carrier and pellets) and thereby enhanced specific antibiotic productivity, 18–28% were observed.     

Two- and three-phase mixing in a concentric draft tube gas-lift fermentor

Two- and three-phase mixing studies were carried out in a 44-L concentric draft tube gas-lift fermentor. It was proposed to use the fermentor for the production of solvents using immobilized bacteria. Bubble size, gas holdup, liquid velocities, circulation, and mixing times were determined for various superficial gas velocities in distilled water, starch, carboxymethyl cellulose, and ethanol solutions. The observed trends for two phase mixing were similar to other studies but the results were found to be more sensitive to liquid properties. This was possibly due to the large value of downcomer to riser area used in this study. Mixing in three phases highlighted the difficulty in predicting the effect of adding solids to the gas-liquid system. Results showed that the gas-lift fermentor was ideally suited to dealing with three phases but more work is necessary before accurate models can be developed to account for the effect of solids.     

Flow‐dependent entrapment of large bioparticles in porous process media

The need for purification of biomolecules extends to larger bioparticles as well. For example, virus purification is required for production of many vaccines and gene delivery vectors, and understanding virus removal in porous media is also important in downstream processing of therapeutic proteins and in purification of water in soils. A convective entrapment mechanism for retention of large bioparticles is discussed here based on retention of such bioparticles in pore constrictions at high enough flow rates, even under non‐binding conditions. A simple equation to predict whether such entrapment is expected to occur in a given system is derived based on a Péclet number that is proportional to the flow rate and to the cube of the bioparticle diameter. To test the theory, adenovirus was spiked onto chromatographic beds. As expected from the theory, under non‐interacting conditions a progressively larger amount of virus becomes trapped with increasing flow rate. The entrapment is reversible upon flow rate reduction, which, within the proposed model, is based on the possibility of diffusive escape from pore constrictions. This mechanism can be exploited for virus purification or removal, and the theory is also consistent with the anecdotal evidence that monoliths and membranes are more difficult to clean than conventional chromatographic beds, especially at high flow rates. Biotechnol. Bioeng. 2009; 104: 127–133 © 2009 Wiley Periodicals, Inc.     

Design and physical characteristics of a multistage,continuous tower fermentor

A multistage tower laboratory fermentor has been constructed consisting of eight compartments separated by sieve plates. Flow of substrate and air is concurrent from the bottom to the top of the column. It, was hoped that this system could be used to reproduce, simultaneously on a continuous basis, eight distinct phases of a batch growth curve. It was believed that the extent of batch curve simulation would depend upon the character of hydraulic mean residence time of broth in the column and in the individual compartments. The expected relationship did not occur. Rather it was found that growth in the column involved residence time characteristics not only for the fluid but also for the microorganisms, and for the growth limiting substrate. Depending upon the column operation, these could be distinct and different. The purpose of this investigation was to study the residence time distribution (RTD) of the continous (fluid) and dispersed (microorganisms) phases for model systems as well as for a yeast fermentation. Various degrees of flow nonideality, i.e., fluid blackflow and dispersed phase sedimentation, were noticed. The former seems to be due to interaction of the concurrent gas and liquid flow; it is particularly dependent upon void area of the sieve plate holes. Sedimentation is probably a function of plate design as well as cell size and density. It wa concluded that for a particular plate design the gas hold-up wass controlled by superficial air velocity and was the main parameter governing the differences between dispersed and continous phase(Rt1). This conclusion was supported by a computeraided styudy utilizing a mathematical model of fluid flow to fit the growth kinetics and cell distribution observed experimentally throughout the fermentor. Some advantages of foam control in the tower fermentor by surface active compounds are mentioned. Also, suggestions are made for carrying out fermentations that have two liquid phases, such as a hydrocarbon fermentation. The possibility of closely approximating plug-flow conditions in the multistage tower fermentor, a necessary condition for batch growth simulation, is discussed from a practical point of view.     

Studies on the production of bacterial rennet in a pilot plant fermentor

An attempt was made to find out the optimum aeration and agitation rates on the production of bacterial rennet from Bacillus sublilis K-26 using 5% wheat bran medium in a 13 liter fermentor. The enzyme activity and the growth rate were shown to increase with an increase in the rate of agitation. The fermentation experiments carried out at an agitation rate of 400 rpm showed an approximate threefold increase in enzyme activity with a considerable decrease in the fermentation time over those agitated at 200 and 300 rpm. The beneficial effect of a higher oxygen rate was observed for enzyme production occurring at a lower agitation rate. The inoculum activity and the varying amounts of antifoam agent which were added showed no apparent effect either on the total incubation time or on the final enzyme activity. It has been suggested that an agitation rate of 400 rpm with an aeration level of 3000 cc/min are the optimum values for the efficient production of bacterial rennet from B. subtilis K-26 using 5% wheat bran medium in a 13 liter fermentor.     

Citric acid production from glucose. II. Growth and excretion kinetics in a trickleflow fermentor

The growth and citric acid production kinetics of Saccharomycopsis lipolytica on glucose is investigated in a trickle-flow fermentor. Liquid hold-up and oxygen-transfer coefficient in the reactor column filled with cylindrical wood chips have been determined and found in agreement with chemical engineering correlations. Citric acid production starts at the end of the growth phase and proceeds at a constant specific rate of 0.025 hr^?1for about 80 hr. The fermentor can then be regenerated by addition of ammonia, which induces new growth and excretion phases. Comparing the metabolic behavior of free and immobilized cells, two main kinetic differences are observed. First, the growth phase is linear with the bound cells instead of exponential in the stirred fermentor. Second, in the trickle-bed fermentor acid productivity and oxygen acid yield are reduced by 30%. Oxygen diffusional limitations, mainly in the biomass film, and alterations in bound cell metabolism are shown to be responsible of the kinetic modifications. Simple modelizations of oxygen diffusion effects are also presented to support the interpretation of the experimental data.     

Stimulation of avermectin B1a biosynthesis in Streptomyces avermilitis by feeding glucose and propionate

The biosynthetic ability of avermectin B1a in Streptomyces avermilitis was improved with propionate addition and glucose feeding. The results showed that B1a production was increased by 12.8–13.8% through supplement of 0.8% propionate at 24 h of cultivation. A stronger stimulation on B1a biosynthesis in S. avermilitis was observed by 3.0% glucose feeding at 5 d of cultivation. The B1a biosynthesis could be further enhanced by repeated glucose fed-batch process in a 10-l bench-top fermentor. A maximal B1a concentration of 780.0 mg/l was obtained by repeated 1.0% glucose addition on 4 d, 5 d and 6 d, which was 2.1-fold higher than that in a control fermentation. Corresponding with this, an additional 6.8% increase of B1a proportion was observed in comparison with the control process. This stimulation on avermectin B1a production was obvious even in a 2000-l fermentor under suitable control of aeration.     

Evaluation of feeding strategies in carbon-regulated secondary metabolite production through mathematical modeling

There is now growing evidence that the production of many secondary metabolic by microorganisms is subjected to carbon-catabolite regulation. Even though the exact mode of this regulation is not yet clear, an engineering analysis of the production process is still possible based upon a suitable hypothesis. By way of simulation of penicillin fermentation data obtained from the literature, a mechanistic model involving a substrate inhibition kinetics of product formation has been verified in this paper. Such a model has been found successful not only in predicting simple sugar-feeding strategy, but also a complicated computer guided strategy based upon controlling biomass growth rates in the tropo and idiophases. Using this model, for strategies for sugar feeding into penicillin fermentation have been investigated. These results show that similar penicillin productivities can be obtained using any of these strategies provided fermentations are carried out under optimal conditions corresponding to the strategy chosen. Effect of maximum oxygen transfer capacity of the fermentor under the conditions of fungal growth has been incorporated using an upper limit of biomass concentration on achievement of which the fermentations must be stopped due to serious oxygen limitations. Results of model simulations with such limits throw light upon the way in which different fermentors may behave with respect to product formation.     

Kinetics of alpha-amylase synthesis from Bacillus amyloliquefaciens

The microbial production of alpha-amylase from Bacillus amyloliquefaciens was investigated. The microorganism was grown using media containing glucose or maltose at 37 degrees C and under aerobic conditions in a 16-L fermentor. The alpha-amylase synthesis from maltose was not found to be inducible but was found to be subject to catabolite repression. The maltose uptake rate was observed to be the rate-limiting step compared to the conversion rate of maltose to glucose by intracellular alpha-glucosidase. The alpha-amylase activity achieved with maltose as a substrate was higher than that achieved with glucose. A slower growth rate and a higher cell density were obtained with maltose. The enzyme production pattern depended upon the nutrient composition of the medium.     

Required minimum granule size in UASB reactor and characteristics variation with size

The objective of this study was to define minimum size of bioparticles that could be classified as granules, to offer all advantages of granular sludge. Based on the theory of sedimentation, the minimum diameter bioparticles, which should be considered as granules was found out for specific gravity of sludge ranging between 1.01 and 1.05. For example, for specific gravity of 1.035 the minimum diameter of granules required for better sludge retention was 0.34 mm. The diameter based on this theory was evaluated by carrying out settling column analysis of a granular sludge obtained from lab-scale UASB reactor and verified with microscopic observation. To find out the effect of granules size on the nature of biodegradability, specific methanogenic activity (SMA) was carried out. It was observed that SMA increased with size of bioparticles tested in the range of 0.27-3.03 mm. The change in VSS/SS ratio and specific gravity was observed with size of granules. Consideration of variation in specific gravity with size of granules increased the degree of validation of sedimentation theory for the calculation of granules diameter.     

Effect of inoculum size on the aeration pattern of batch cultures of a fungal microorganism

Trichoderma reesei QM 9123 has been grown in batch culture in a 10 liter stirred fermentor, at a temperature of 30°C and pH 4.0. The fermentor was operated at a single stirrer speed of 400 rpm and air rate of 1 v/v/m. The effect of four inoculum sizes (0.5, 1.0, 3.0 and 5.0%) on the growth pattern and the aeration profiles was examined. Logarithmic growth of the fungus was observed. The aeration profile changed with inoculum size and at 5.0%, it was found that the oxygen uptake rate was controlled by the oxygen supply rate, during which the oxygen tension was zero.     

An experimental study of acid production rate controlled operations of a continuous fermentor

The efficacy of acid production rate (APR) controlled operations of a continuous fermentor supporting the growth of a methylotroph, L3, was experimentally examined. Direct digital control of pH at a constant value allowed for on-line estimation of APR during the fermentation. Two types of APR controlled operations were studied. In the first type of operation, the APR was controlled at a constant value according to a predetermined program by manipulating the feed flow rate to the fermentor. Such an operation effectively stabilized the cell mass productivity of a continuous fermentor subjected to disturbances in the feed nutrient concentration. It resulted in a near complete conversion of methanol to yield a cell mass product with very low amounts of unutilized methanol at both steady state and transient fermentation situations. In the second type of operation, the feed flow rate was manipulated to optimize the steady state value of APR during the fermentation. This method shows promise for on-line steady state optimization of cell mass productivity in a continuous fermentor.