Scale-up strategy for bioreactors with Newtonian and non-Newtonian broths

In the scale-up of bioreactors one of the most commonly used criteria for aerobic processes is to keep the oxygen transfer coefficient constant. Nevertheless, the reproduction of the behaviour of a cell population at different scales is not dependent just on the oxygen transfer capability but rather on the oxygen transfer rate, that must be high enough to cope with the oxygen demand of the culture. In this work a strategy of scale-up is proposed based in geometric similarity, constant impeller tip speed, and constant oxygen transfer rate. The effects of the dissolved oxygen concentration, the scale-up ratio and the rheology of the broth are analysed.     

Quantification of power consumption and oxygen transfer characteristics of a stirred miniature bioreactor for predictive fermentation scale-up

Miniature parallel bioreactors are becoming increasingly important as tools to facilitate rapid bioprocess design. Once the most promising strain and culture conditions have been identified a suitable scale-up basis needs to be established in order that the cell growth rates and product yields achieved in small scale optimization studies are maintained at larger scales. Recently we have reported on the design of a miniature stirred bioreactor system capable of parallel operation [Gill et al. (2008); Biochem Eng J 39:164-176]. In order to enable the predictive scale-up of miniature bioreactor results the current study describes a more detailed investigation of the bioreactor mixing and oxygen mass transfer characteristics and the creation of predictive engineering correlations useful for scale-up studies. A Power number of 3.5 for the miniature turbine impeller was first established based on experimental ungassed power consumption measurements. The variation of the measured gassed to ungassed power ratio, P(g)/P(ug), was then shown to be adequately predicted by existing correlations proposed by Cui et al. [Cui et al. (1996); Chem Eng Sci 51:2631-2636] and Mockel et al. [Mockel et al. (1990); Acta Biotechnol 10:215-224]. A correlation relating the measured oxygen mass transfer coefficient, k(L)a, to the gassed power per unit volume and superficial gas velocity was also established for the miniature bioreactor. Based on these correlations a series of scale-up studies at matched k(L)a (0.06-0.11 s(-1)) and P(g)/V (657-2,960 W m(-3)) were performed for the batch growth of Escherichia coli TOP10 pQR239 using glycerol as a carbon source. Constant k(L)a was shown to be the most reliable basis for predictive scale-up of miniature bioreactor results to conventional laboratory scale. This gave good agreement in both cell growth and oxygen utilization kinetics over the range of k(L)a values investigated. The work described here thus gives further insight into the performance of the miniature bioreactor design and will aid its use as a tool for rapid fermentation process development.     

Volumetric scale-up of a three stage fermentation system for food waste treatment

In this study, a volumetric scale-up of this system was designed and built on a field pilot-scale (total digester volume 10 m(3)), with the results from the field pilot-scale experiments compared with those from the bench-scale (total digester volume 0.4 m(3)) process prior to scale-up. The reduction rate of total chemical oxygen demand (tCOD) and the maximum methane content produced in the biogas from the bench-scale system were 90.6% and 72%; whereas those from the field pilot-scale system were 90.1% and 68%, respectively. The estimated methane yields were 282 and 254 l CH(4)/kg tCOD(degraded) in bench and field pilot-scale fermentation systems, respectively. These results indicate that the three stage fermentation system developed in this study can be applied as a commercial process for the disposal of food waste in view of process stability.     

A microwell platform for the scale-up of a multistep bioconversion to bench-scale reactors: Sitosterol side-chain cleavage

The microwell-scale approach is widely used for screening purposes and one-pot biotransformations, but it has seldom been applied to complex whole cell multistep bioconversions, requiring prolonged incubation periods. The present study aims to contribute to filling this gap. The side-chain cleavage of sitosterol to androstenedione (AD) with Mycobacterium sp. NRRL B-3805 cells was used as a model system, and focus was given to the screening of suitable bioconversion media with 24-well microwell plates. Results show that to perform this particular bioconversion growing cells are preferred over resting cells due to higher conversion yields obtained in aqueous medium. The use of resting cells may nevertheless present an interesting approach provided catalytic activity is retained throughout successive runs. Maintaining suitable aeration levels (air flow of 1 mL/min) allowed minimizing the decay of catalytic activity typically observed alongside consecutive bioconversion runs with resting cells. Microwell plates with dedicated oxygen and pH monitoring capabilities proved effective in media development for complex multistep bioconversions using relatively slow-growing bacteria. Under constant k_La (0.044/s) similar AD production and dissolved oxygen profiles were observed in microwell plates and in a bench-scale reactor. Selection of a suitable k_La value proved critical, since under lower k_La values scale-up proved unsuccessful. The same pattern was observed when other scale-up criteria were evaluated to perform the scale-up of this particular bioconversion. Results gathered seem to validate the proposed approach “from microwell plate to bench-scale fermentor”.     

Ambruticin S production in air-lift and stirred-tank bioreactors

Summary Using the method of equi-inocular synchronized comparative fermentation (EISCF) the cultivation of Sorangium cellulosum So ce 10 and production of the polyketide antibiotic ambruticin S was compared in stirred-tank and air-lift reactors of different geometry. This method requires that inocula originate from the same pre-culture and cultivation parameters are synchronized to similar values. Similar ambruticin yields were obtained from both reactor systems provided that the concentration of dissolved oxygen (DO) was maintained above a certain value (ca. 40%). For cultivation of S. cellulosum it is the DO level rather than the oxygen transfer rate which presents the proper criterion for scale-up and comparative reactor studies. Offprint requests to: W.-D. Deckwer     

Oxygen transfer and scale-up in bioreactors using hydro-ejectors for gas-liquid contacting

The commonly used scale-up criteria are investigated for their applicability in the case of hydro-ejector reactors. In combination with the liquid jet momentum, which characterizes the hydro-ejector, a scale-up correlation with the oxygen transfer rate as scale-up criterion is proposed, independent of the type of hydro-ejector and the reactor configuration. The results with regard to the power input are compared with those of stirred tank and bubble column. Its competitiveness is at high power per volume input and above all in large scale reactors.     

Developing a scalable model of recombinant protein yield from Pichia pastoris: the influence of culture conditions, biomass and induction regime

Background  

The optimisation and scale-up of process conditions leading to high yields of recombinant proteins is an enduring bottleneck in the post-genomic sciences. Typical experiments rely on varying selected parameters through repeated rounds of trial-and-error optimisation. To rationalise this, several groups have recently adopted the 'design of experiments' (DoE) approach frequently used in industry. Studies have focused on parameters such as medium composition, nutrient feed rates and induction of expression in shake flasks or bioreactors, as well as oxygen transfer rates in micro-well plates. In this study we wanted to generate a predictive model that described small-scale screens and to test its scalability to bioreactors.     

Effects of fermentation feeding strategies prior to induction of expression of a recombinant malaria antigen inEscherichia coli

Summary A variety of feeding strategies have been described for attaining high cell densities in fed-batch fermentors. Although cell density is an important component in the produtivity of recombinant fermentations, it must be achievable with high product expression levels. Experiments were conducted to study the influence of fermentation feeding strategies on the production of a recombinant malaria antigen inEscherichia coli. C-source feeding profiles were calculated to maintain specific growth rates at 0.1, 0.2, 0.35, and 0.5 l/h prior to induction in defined and complex media using an exponential growth model. Fed-batch fermentations employing these feeding profiles effectively controlled the specific growth rates prior to induction. Antigen yields per dry cell weight did not vary with specific growth rate. Antigen yields from fed-batch fermentations achieving high cell densities were similar to batch fermentations achieving low cell densities. These results show that C-feeding policies can limit growth without reducing expression levels in some systems, and suggest applications in managing oxygen demand and catabolic by-product formation during process scale-up.     

Modelling of the process yields of a whey fermentation

Summary The biomass yields (y) and COD reduction efficiencies (η) of a whey fermentation by Kluyveromyces fragilis were studied in a 100-1 fermenter at various stirrer speeds and lactose concentrations, and compared to those obtained in 10-1 and 15-1 fermenters at constant values of the oxygen transfer coefficient (k_La) and air velocity. The empirical models previously constructed by using the 15-1 fermenter data could be used to predict the yields on the other scales by calculating for each run the 15-1 fermenter which would provide the same oxygen transfer coefficient measured by the sulphite method on each fermenter under study. To make this model independent of stirrer speeds used in each generic fermenter, the effect of aeration and mixing was incorporated into an overall parameter (k_La) and the values of y and η were correlated only with temperature, lactose level and k_L a, since these variables were approximately orthogonal. The validity of this model was finally checked against the yields reported by Wasserman et al. (1961) in a 6-m³ fermenter, thus confirming the capability of the model to provide a reliable basis for further scale-up on the production scale.     

Scale-up of dialysis fermentation for high cell density cultivation of Escherichia coli.

In dialysis fermentations inhibiting metabolites can be removed from cell suspensions resulting in a prolonged exponential growth phase and higher production yields. Because of successful high cell density cultivations of Escherichia coli in a laboratory dialysis reactor, a scale-up of the process was investigated. To provide sufficient membrane area for dialysis in a technical scale fermenter, an external membrane module was used, that was also applied for oxygen supply to the culture in the external loop. Cultivations with recombinant E. coli K12, with and without induction, in 2- and 300-l reactors were carried out using external modules. Cell densities exceeding 190 g l(-1), previously obtained in laboratory dialysis fermentation, were also produced with external dialysis modules. Protein concentration in a 300-l reactor was increased to the 3.8-fold of industrial fed-batch-fermentations.     

Oxygen transfer and energy dissipation rate in surface aerator

The dissipation rate of turbulent kinetic energy (ε) is a key parameter for mixing in surface aerators. In particular, determination ε across the impeller stream, where the most intensive mixing takes place, is essential to ascertain that an appropriate degree of mixing is achieved. Present work by using commercial software VisiMix^® calculates the energy dissipation rate in geometrically similar unbaffled surface aeration systems in order to scale-up the oxygen transfer process. It is found that in geometrically similar system, oxygen transfer rate is uniquely correlated with dissipation rate of energy. Simulation or scale-up equation governing oxygen transfer rate and dissipation rate of energy has been developed in the present work.     

Development of a single-pass ceramic matrix bioreactor for large-scale mammalian cell culture

A single-pass, plug-flow bioreactor has been developed in which oxygen is supplied to entrapped hybridoma cells via sllicone tubes threaded through the square channels of a macroporous ceramic monolith. Oxygen diffuses from the gas phase, through the silicone tubing, across the open square channel, and into the pores of the ceramic wall where it is consumed by entrapped cells. Advantages of such a reactor include higher product yields, protection of cells from detrimental hydrodynamic effects, no internal moving parts to compromise asepsis, and simplicity of operation. A prototype bioreactor was constructed and operated over a range of residence times. A side-by-side experimental comparison with a conventional recycle bioreactor was performed by inoculating both bioreactors with cells from the same stock culture and feeding medium from the same reservoir. Final antibody titers were 80% higher in the single-pass bioreactor at a residence time of 200 minutes compared with those of the recycle bioreactor at a residence time of 800 minutes. A theoretical analysis of oxygen transport in this bioreactor is developed to highlight important design criteria and operating strategies for scale-up. (c) 1992 John Wiley & Sons, Inc.     

Large-scale bioventing degradation rates of petroleum hydrocarbons and determination of scale-up factors

Bioventing is a cutting edge, nondestructive treatment method that uses indigenous soil microorganisms in situ to remediate petroleum hydrocarbons in the unsaturated soil zone. Transferring the application of this technology to a field environment still has some uncertainties due to scale-up challenges. In order to identify the scale-up factor, a 80-kg soil reactor system was developed, consisting of a custom-made reactor, climate chamber, low-flow venting system, and an off-gas capture device. Sandy and clayey soils were tested with known concentrations of spiked synthetic gasoline. Various environmental conditions were monitored, which included moisture levels, pH, microbial levels, and nutrient and oxygen levels. Results show a second-stage degradation rate similar to the degradation rate obtained from research conducted with a 4-kg reactor, giving an average scale-up factor of 2.3 ± 0.4. The completed research shows that working with a 80-kg laboratory reactor is feasible, yet not always necessary for the development of scale-up factors. A complimentary study with aged soil contaminants was performed and yielded degradation rates that were significantly reduced.     

Aeration of concentrated activated sludge

A multiphase project has been planned to develop a new biological process capable of economically treating high BOD wastes. Herein is presented the results of the first phase of the program, in which the feasibility of growing concentrated microbial cultures was investigated and the oxygen and power requirements for maintaining such cultures were determined. An example is given of the scale-up of power requirements for oxygen transfer in a prototype system.     

The scale-up of plant cell culture: Engineering considerations

The enormous versatility of plants has continued to provide the impetus for the development of plant tissue culture as a commercial production strategy for secondary metabolites. Unfortunately problems with slow growth rates and low products yields, which are generally non-growth associated and intracellular, have made plant cell culture-based processes, with a few exceptions, economically unrealistic. Recent developments in reactor design and control, elicitor technology, molecular biology, and consumer demand for natural products, are fuelling a renaissance in plant cell culture as a production strategy. In this review we address the engineering consequences of the unique characteristics of plant cells on the scale-up of plant cell culture.Abbreviations a gas-liquid interfacial area per volume - C dissolved oxygen concentration - C^* liquid phase oxygen concentration in equilibrium with the partial pressure of oxygen in the bulk gas phase - K_L overall mass transfer coefficient - k_L liquid film mass transfer coefficient - m_O2 cell maintenance coefficient for oxygen - OTR oxygen transfer rate - OUR oxygen uptake rate - pO₂ partial pressure of oxygen - STR stirred-tank reactor - v.v.m. volume of gas fed per unit operating volume of reactor per minute - X biomass concentration - Y_x/O2 biomass yield coefficient for oxygen - specific growth rate     

Scale-down of oxygen and glucose fluctuations in a tubular photobioreactor operated under oxygen-balanced mixotrophy

Oxygen-balanced mixotrophy (OBM) is a novel type of microalgal cultivation that improves autotrophic productivity while reducing aeration costs and achieving high biomass yields on substrate. The scale-up of this process is not straightforward, as nonideal mixing in large photobioreactors might have unwanted effects in cell physiology. We simulated at lab scale dissolved oxygen and glucose fluctuations in a tubular photobioreactor operated under OBM where glucose is injected at the beginning of the tubular section. We ran repeated batch experiments with the strain Galdieria sulphuraria ACUF 064 under glucose pulse feeding of different lengths, representing different retention times: 112, 71, and 21 min. During the long and medium tube retention time simulations, dissolved oxygen was depleted 15–25 min after every glucose pulse. These periods of oxygen limitation resulted in the accumulation of coproporphyrin III in the supernatant, an indication of disruption in the chlorophyll synthesis pathway. Accordingly, the absorption cross-section of the cultures decreased steeply, going from values of 150–180 m² kg⁻¹ at the end of the first batch down to 50–70 m² kg⁻¹ in the last batches of both conditions. In the short tube retention time simulation, dissolved oxygen always stayed above 10% air saturation and no pigment reduction nor coproporphyrin III accumulation were observed. Concerning glucose utilization efficiency, glucose pulse feeding caused a reduction of biomass yield on substrate in the range of 4%–22% compared to the maximum levels previously obtained with continuous glucose feeding (0.9 C-g C-g⁻¹). The missing carbon was excreted to the supernatant as extracellular polymeric substances constituted by carbohydrates and proteins. Overall, the results point out the importance of studying large-scale conditions in a controlled environment and the need for a highly controlled glucose feeding strategy in the scale-up of mixotrophic cultivation.     

Fed-batch bioreactor process scale-up from 3-L to 2,500-L scale for monoclonal antibody production from cell culture

This case study focuses on the scale-up of a Sp2/0 mouse myeloma cell line based fed-batch bioreactor process, from the initial 3-L bench scale to the 2,500-L scale. A stepwise scale-up strategy that involved several intermediate steps in increasing the bioreactor volume was adopted to minimize the risks associated with scale-up processes. Careful selection of several available mixing models from literature, and appropriately applying the calculated results to our settings, resulted in successful scale-up of agitation speed for the large bioreactors. Consideration was also given to scale-up of the nutrient feeding, inoculation, and the set-points of operational parameters such as temperature, pH, dissolved oxygen, dissolved carbon dioxide, and aeration in an integrated manner. It has been demonstrated through the qualitative and the quantitative side-by-side comparison of bioreactor performance as well as through a panel of biochemical characterization tests that the comparability of the process and the product was well controlled and maintained during the process scale-up. The 2,500-L process is currently in use for the routine clinical production of Epratuzumab in support of two global Phase III clinical trials in patients with lupus. Today, the 2,500 L, fed-batch production process for Epratuzumab has met all scheduled batch releases, and the quality of the antibody is consistent and reproducible, meeting all specifications, thus confirming the robustness of the process.     

Study and modeling of fluctuating dissolved oxygen concentration impact on Corynebacterium glutamicum growth in a scale-down bioreactor

In this study, the impact of dissolved oxygen concentrations oscillations on Corynebacterium glutamicum 2262 ΔldhA growth was studied experimentally and modeled. Aiming at this, a dedicated two-compartment scale down set-up composed of two interconnected aerobic/anaerobic stirred tank bioreactors was used. The mean residence time of bacteria in each compartment was modified by adapting circulation rates and culture volumes in each bioreactor and the resulting temporal ratio of aeration was calculated. The five growth kinetics were then modeled using an original kinetic model coupling Monod growth modeling and the Residence Time Distributions. Our study showed that the microbial growth rate and macroscopic yields were clearly linked to the temporal ratio of aeration, allowing the definition of simple but robust law for process scale-up purpose. It was also revealed that the model proposed precisely agreed with the experimental growth data, whatever the fractions of aeration time imposed experimentally.     

以摇瓶所得摄氧率为基准进行发酵放大

通过设计特殊摇瓶,用亚硫酸盐法测出摇瓶口纱布层氧通透率的基础上,在实际发酵情况下通过测定瓶内气、液相氧的变化得出其发酵过程中的摄氧率(OUR)及氧传递系数(K_La)。以特制摇瓶取得的菌体CUR为基准进行发酵过程和发酵罐的放大。通过质谱仪在线检测及采样分析,研究了3种不同供气流量及搅拌转速下的放大结果。摇瓶与发酵罐在菌体OUR、菌体产量方面吻合很好,而在整个放大过程中,发现摇瓶与发酵罐内的氧传递系数(K_La)、溶解氧(C_L)差异较大。