Observability analysis of biochemical process models as a valuable tool for the development of mechanistic soft sensors

By enabling the estimation of difficult‐to‐measure target variables using available indirect measurements, mechanistic soft sensors have become important tools for various bioprocess monitoring and control scenarios. Despite promising higher process efficiencies and increased process understanding, widespread application of soft sensors has been stalled by uncertainty about the feasibility and reliability of their estimations given present process analytical constraints. Observability analysis can provide an indication of the possibility and reliability of soft sensor estimations by analyzing the structural properties of first‐principle (mechanistic) models. In addition, it can provide a criteria for selection of suitable measurement methods with respect to their information content; thereby leading to successful implementation of soft sensors in bioprocess development and manufacturing environments. We demonstrate the utility of observability analysis for two classes of upstream bioprocesses: the processes involving growth and ethanol formation by Saccharomyces cerevisiae and the process of penicillin production by Penicillium chrysogenum. Results obtained from laboratory‐scale cultivations in addition to in‐silico experiments enable a comparison of theoretical aspects of observability analysis and the real‐life performance of soft sensors. By taking the expected error of measurements provided to the soft sensor into account, an innovative scaling approach facilitates a higher degree of comparability of observability results among various measurement configurations and process conditions. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1703–1715, 2015     

Changes in the concentrations of Na+, K+ and Cl? in secretion from the skin during progressive increase in exercise intensity

A simple method for sampling skin secretion in 1-min periods was developed for investigating the effects of progressive increases in exercise intensity on Na+, K+ and Cl- secretions from the skin of the forearm. Ten healthy male subjects performed exercise consisting of eight stepwise increases in intensity from 50 to 225 W, with a 25-W increase at each step. Exercise at each step was for 3 min followed by a 1-min recovery period. Samples of blood and skin secretion were taken during the recovery period. Significant positive correlations were found between the mean concentrations of Na+ and Cl- and between those of K+ and Cl- in the skin secretion. The concentrations of electrolytes in the skin secretion also showed significant correlations with the blood lactate concentrations. The inflection points for secretions of Na+, K+ and Cl- were 4.04, 3.61 and 3.83 mmol.l-1 of blood lactate; 64.42, 61.96 and 62.14% of maximal oxygen consumption (VO2max); and exercise intensities of 123.01, 117.65 and 125.07 W, respectively. No significant differences were observed between the value of 67.27% of VO2max or 134.00W at the onset of blood lactate accumulation (OBLA) and the inflection points. From these results we concluded that changes in electrolyte concentrations in skin secretion during incremental exercise according to this protocol were closely related with the change in the blood lactate concentration, and that the inflection points for electrolytes may have been near the exercise intensity at OBLA.     

Immobilization of glucose oxidase and lactate dehydrogenase onto magnetic nanoparticles for bioprocess monitoring system

Glucose oxidase (GOD) and lactate dehydrogenase (LDH) were immobilized onto magnetic nanoparticles, viz. Fe₃O₄, via carbodiimide and glutaraldehyde. The immobilization efficiency was largely dependent upon the immobilization time and concentration of glutaraldehyde. The magnetic nanoparticles had a mean diameter of 9.3 nm and were superparamagnetic. The immobilization of GOD and LDH on the nanoparticles slightly decreased their saturation magnetization. However, the FT-IR spectra showed that GOD and LDH were immobilized onto the nanoparticles by different binding mechanisms, the reason for which was not well explained. The optimum pH values of the immobilized GOD and LDH were changed to 8 and 10, respectively. The free and immobilized enzyme kinetic parameters (K_m and V_max) were determined by Michaelis-Menten enzyme kinetics. The Km values for free and immobilized GOD were 0.168 and 0.324 mM, respectively, while those for free and immobilized LDH were 0.19 and 0.163 mM for NAD, and 2.976 and 4.785 mM for lactate, respectively. High operational stability was observed, with more than 80% of the initial enzyme activity being retained for the immobilized GOD up to 12 h and for the immobilized LDH up to 24 h. The immobilized GOD was applied to a sequential injection analysis system for the application of bioprocess monitoring.     

Severe hypoxia decreases oxygen uptake relative to intensity during submaximal graded exercise

The effect of severe acute hypoxia (fractional concentration of inspired oxygen equalled 0.104) was studied in nine male subjects performing an incremental exercise test. For power outputs over 125 W, all the subjects in a state of hypoxia showed a decrease in oxygen consumption ( O₂) relative to exercise intensity compared with normoxia (P < 0.05). This would suggest an increased anaerobic metabolism as an energy source during hypoxic exercise. During submaximal exercise, for a given O₂, higher blood lactate concentrations were found in hypoxia than in normoxia (P < 0.05). In consequence, the onset of blood lactate accumulation (OBLA) was shifted to a lower O₂ ( O₂ 1.77 l·min^–1 in hypoxia vs 3.10 l·min^–1 in normoxia). Lactate concentration increases relative to minute ventilation ( _E) responses were significantly higher during hypoxia than in normoxia (P < 0.05). At OBLA, _E during hypoxia was 25% lower than in the normoxic test. This study would suggest that in hypoxia subjects are able to use an increased anaerobic metabolism to maintain exercise performance.     

Expert systems in the control of animal cell culture processes: Potentials,functions, and perspectives

In recent years, the development of advanced systems for bioprocess monitoring and control has become an area of intensive research. Along with traditional techniques, there are several new approaches which are increasingly being applied to bioprocess operations. Among these, of special note is expert system technology, which provides possibilities for the design of efficient bioprocess control systems with new functional capabilities. This technology has been successfully applied to variety of microbial processes at laboratory and industrial scale. The present paper analyzes the possibility for application of expert systems to animal cell cultures processes whose high complexity is well suited to expert control. The discussion focuses on the organization and the functionality of the intelligent control systems, and covers some practical aspects of their design.     

Progress toward forecasting product quality and quantity of mammalian cell culture processes by performance‐based modeling

The production of biopharmaceuticals requires highly sophisticated, complex cell based processes. Once a process has been developed, acceptable ranges for various control parameters are typically defined based on process characterization studies often comprising several dozens of small scale bioreactor cultivations. A lot of data is generated during these studies and usually only the information needed to define acceptable ranges is processed in more detail. Making use of the wealth of information contained in such data sets, we present here a methodology that uses performance data (such as metabolite profiles) to forecast the product quality and quantity of mammalian cell culture processes based on a toolbox of advanced statistical methods. With this performance based modeling (PBM) the final product concentration and 12 quality attributes (QAs) for two different biopharmaceutical products were predicted in daily intervals throughout the main stage process. The best forecast was achieved for product concentration in a very early phase of the process. Furthermore, some glycan isoforms were predicted with good accuracy several days before the bioreactor was harvested. Overall, PBM clearly demonstrated its capability of early process endpoint prediction by only using commonly available data, even though it was not possible to predict all QAs with the desired accuracy. Knowing the product quality prior to the harvest allows the manufacturer to take counter measures in case the forecasted quality or quantity deviates from what is expected. This would be a big step towards real‐time release, an important element of the FDA's PAT initiative. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1119–1127, 2015     

Industrial bioprocess control and optimization in the context of systems biotechnology

The developments of the systems biotechnology and its application in the industrial process open up new horizons to industrial biotechnology. The unprecedented understanding of the relationships between cellular behaviors and the surrounding environments during the bioprocess has been achieved. In this paper, we review new advances in the strain improvement, bioprocess control and optimization. The holistic viewpoints and ideas applied in industrial bioprocesses and their future prospects are discussed by illustrating some successful cases.     

The use of critical power as a determinant for establishing the onset of blood lactate accumulation

Eight highly trained male kayakers were studied to determine the relationship between critical power (CP) and the onset of blood lactate accumulation (OBLA). Four exercise sessions of 90 s, 240 s, 600 s, and 1200 s were used to identify the CP of each kayaker. Each individual CP was obtained from the line of best fit (LBF_CP) obtained from the progressive work output/time relationships. The OBLA was identified by the 4 mmol·l^–1 blood lactate concentration and the work output at this level was determined using a lactate curve test. This consisted of paddling at 50 W for 5 min after which a 1-min rest was taken during which a 25-l blood sample was taken to analyse for lactate. Exercise was increased by 50 W every 5 min until exhaustion, with the blood sample being taken in the 1-min rest period. The exercise intensity at the OBLA for each subject was then calculated and this was compared to the exercise intensity at the LBF_CP. The intensity at LBF_CP was found to be significantly higher (t=2.115, P<0.05) than that at the OBLA of 4 mmol·1^–1. These results were further confirmed by significant differences being obtained in blood lactate concentration (t=8.063, P<0.05) and heart rate values (t=2.90, P<0.05) obtained from the exercise intensity at LBF_CP over a 20-min period and that of the anaerobic threshold (Th_an) parameters obtained from the lactate/heart rate curve. These differences suggest that CP and Th_an are different physiological events and that athletes have utilised either one or the other methods for monitoring training and its effects.     

Scale-up on basis of structured mixing models: A new concept

A new scale-up concept based upon mixing models for bioreactors equipped with Rushton turbines using the tanks-in-series concept is presented. The physical mixing model includes four adjustable parameters, i.e., radial and axial circulation time, number of ideally mixed elements in one cascade, and the volume of the ideally mixed turbine region. The values of the model parameters were adjusted with the application of a modified Monte-Carlo optimization method, which fitted the simulated response function to the experimental curve. The number of cascade elements turned out to be constant (N = 4). The model parameter radial circulation time is in good agreement with the one obtained by the pumping capacity. In case of remaining parameters a first or second order formal equation was developed, including four operational parameters (stirring and aeration intensity, scale, viscosity). This concept can be extended to several other types of bioreactors as well, and it seems to be a suitable tool to compare the bioprocess performance of different types of bioreactors. (c) 1994 John Wiley & Sons, Inc.