Effect of bioreactor configuration on substrate uptake by cell suspension cultures of the plant Eschscholtzia californica

Summary The uptake of carbohydrates and oxygen by cell suspension cultures of the plant Eschscholtzia californica (California poppy) was studied in relation to biomass production in shake flasks, a 1-1 stirred-tank bioreactor and a 1-1 pneumatically agitated bioreactor. The sequence of carbohydrate uptake was similar in all cases, with sucrose hydrolysis occurring followed by the preferential uptake of glucose. The uptake of fructose was found to be affected by the oxygen supply rate. Carbohydrate utilization occurred at a slower rate in the bioreactors. Apparent biomass yields, Y _X/S, ranged from 0.42 to 0.50 g biomass/g carbohydrate, while true biomass yields, Y _X/S, were about 0.69 g/g. The maintenance coefficient for carbohydrate, m _S, ranged between 0.002 and 0.008 g/dry weight (DW) per hour. The maximum measured specific oxygen uptake rate was 0.56 mmol O₂/g DW per hour and occurred early in the growth stage. The decline in specific uptake rate coincided with a decline in cell viability. The oxygen uptake rate was faster in shake flasks, corresponding to the higher growth rate obtained. The true growth yield on oxygen, YX/O₂, was calculated to range from 0.83 to 1.23 g biomass/g O₂, while the maintenance coefficient, mO₂, ranged from 0.15 to 0.25 mmol O₂/g DW per hour. The growth yields for oxygen determined from the stoichiometry of an elemental balance were within 10% of those calculated from experimental data. Offprint requests to: Raymond L. Legge     

Fed-batch bioreactor performance and cell line stability evaluation of the artificial chromosome expression technology expressing an IgG1 in Chinese hamster ovary cells

The artificial chromosome expression (ACE) technology system uses an engineered artificial chromosome containing multiple site-specific recombination acceptor sites for the rapid and efficient construction of stable cell lines. The construction of Chinese hamster ovary(CHO) cell lines expressing an IgG1 monoclonal antibody (MAb) using the ACE system has been previously described (Kennard et al., Biotechnol Bioeng. 2009;104:540-553). To further demonstrate the manufacturing feasibility of the ACE system, four CHO cell lines expressing the human IgG1 MAb 4A1 were evaluated in batch and fed-batch shake flasks and in a 2-L fed-batch bioreactor. The batch shake flasks achieved titers between 0.7 and 1.1 g/L, whereas the fed-batch shake flask process improved titers to 2.5–3.0 g/L. The lead 4A1 ACE cell line achieved titers of 4.0 g/L with an average specific productivity of 40 pg/(cell day) when cultured in a non optimized 2-L fed-batch bioreactor using a completely chemically defined process. Generational stability characterization of the lead 4A1-expressing cell line demonstrated that the cell line was stable for up to 75 days in culture. Product quality attributes of the 4A1 MAb produced by the ACE system during the stability evaluation period were unchanged and also comparable to existing expression technologies such as the CHO-dhfr system. The results of this evaluation demonstrate that a clonal, stable MAb-expressing CHO cell line can be produced using ACE technology that performs competitively using a chemically defined fed-batch bioreactor process with comparable product quality attributes to cell lines generated by existing technologies.     

Production of vitamin B12 by gram-variable methanol-utilizing bacteria

Summary Vitamin B12 production by two gram-variable methanol-utilizing bacteria was reported. Effects of growth conditions on vitamin B12 productivity were examined in shake flasks. The maximal vitamin B12 production was 227 g per liter of the whole culture broth.     

Production of carotenoids and lipids by <Emphasis Type="Italic">Rhodococcus opacus</Emphasis> PD630 in batch and fed-batch culture

Production of carotenoids by Rhodococcus opacus PD630 is reported. A modified mineral salt medium formulated with glycerol as an inexpensive carbon source was used for the fermentation. Ammonium acetate was the nitrogen source. A dry cell mass concentration of nearly 5.4 g/L could be produced in shake flasks with a carotenoid concentration of 0.54 mg/L. In batch culture in a 5 L bioreactor, without pH control, the maximum dry biomass concentration was ~30 % lower than in shake flasks and the carotenoids concentration was 0.09 mg/L. Both the biomass concentration and the carotenoids concentration could be raised using a fed-batch operation with a feed mixture of ammonium acetate and acetic acid. With this strategy, the final biomass concentration was 8.2 g/L and the carotenoids concentration was 0.20 mg/L in a 10-day fermentation. A control of pH proved to be unnecessary for maximizing the production of carotenoids in this fermentation.     

Inoculum effects on fungal morphology: Shake flasks vs agitated bioreactors

Summary Image analysis has been used to investigate the effect of spore inoculum concentration on the subsequent morphology of Penicillium chrysogenum grown in both shake flasks and a 6L agitated bioreactor. Even with the same inoculum concentration, differences were found between the two systems in the eventual morphology of both the freely dispersed mycelia and the mycelial aggregates or clumps.     

Hydantoinase activity of immobilized non-growing Pseudomonas putida cells

Summary Hydantoinase (dihydropyrimidinase E.C. 3.5.2.2) activity of Pseudomonas putida DSM 84 was evaluated using cells immobilized in alginate beads and in a microporous hollow fibre bioreactor. Conversion of dihydrouracil into N-carbamyl--alanine was most efficient with alginate-immobilized cells. A 40 to 45% conversion was obtained in shake flasks and in continuous mode with packed bed columns. The highest volumetric productivity was obtained with a packed bed column operated at a dilution rate of 0.5 h^-1 (99 g of product. 100 l^-1 per hour). After 96 h the alginate beads began to swell and break apart; no free cells were detected however. Despite some initial loss of cells from the microporous hollow fibre bioreactor, a steady state was later established and maintained for 400 h at dilution rates of 0.1 and 0.25 h^-1.     

Effects of cultivation conditions on the production of heterologous α-galactosidase by Kluyveromyces lactis

Growth conditions relevant for the large-scale production of heterologous proteins with yeasts were studied on a laboratory scale. A strain of Kluyveromyces lactis, containing 15 copies of an expression cassette encoding guar -galactosidase integrated into its ribosomal DNA, was used as a model. By using urea as a nitrogen source, it was possible to produce active extracellular -galactosidase in shake-flask cultures grown on a defined mineral medium. Inclusion of urea instead of ammonium sulphate prevented unwanted acidification of cultures. With urea-containing mineral medium, enzyme production in shake flasks was comparable to that in complex media containing peptone. In contrast, the presence of peptone was required to achieve high productivity in chemostat cultures. The low productivity in chemostat cultures growing on mineral media was not due to loss oft the expression cassette, since addition of peptone to such cultures resulted in an immediate high rate of -galactosidase production. The discrepancy between the behaviour of shake-flask and chemostat cultures during growth on mineral medium illustrates the necessity of physiological studies for the scalling-up of heterologous protein production from laboratory to production scale.     

Influence of culture conditions on thermostable lipase production by a thermophilic alkalitolerant strain ofBacillus sp

The effect of different culture conditions on thermostable lipase production byBacillus sp. was studied in shake flasks. A maximum enzyme activity of 67–75 nkat/mL was observed in a medium consisting of 0.5% soybean flour and 0.1% stearyl glycerol esters or natural fats. A lipase activity of about 117 nkat/mL was established when the cultivation was carried out in laboratory fermentor at 20% minimal dissolved oxygen level, the enzyme production being increased 1.5 fold compared to that in a flask culture.     

Production of carbonyl reductase by Metschnikowia koreensis

A new strain of the yeast Metschnikowia koreensis was grown in shake flasks and a stirred bioreactor for the production of carbonyl reductase. The optimal conditions in the bioreactor for maximizing the biomass specific activity of the enzyme were found to be: a medium composed of glucose (20 g/L), peptone (5 g/L), yeast extract (5 g/L) and zinc sulfate (0.3g/L); the pH controlled at 7; the temperature controlled at 25 °C; an agitation speed of 500 rpm; and an aeration rate of 0.25 vvm. In the bioreactor, a biomass specific enzyme activity of 115.6 U/gDCW was obtained and the maximum biomass concentration was 15.3 gDCW/L. The biomass specific enzyme activity obtained in the optimized bioreactor culture was 11-fold higher than the best result achieved in shake flasks. The bioreactor culture afforded a 2.7-fold higher biomass concentration than could be attained in shake flasks.     

Morphogenetic and nutritional studies of Geotrichum lactis cells

Summary Geotrichum lactis was grown in culture media with different carbon and nitrogen sources. Biotin is needed as a growth factor. During incubation in shake flasks mycelium and arthrospores are produced. Under certain conditions, such as low pH, there is a new form that we have called yeast-like form. This thick-walled form develops from mature arthrospores. The arthrospore and the yeastlike cells have walls with different chemical and structural composition, as observed in the electron microscope, and in their resistance to some lytic extracts.     

Infection of hairy roots of strawberry (Fragaria x Ananassa Duch.) with arbuscular mycorrhizal fungus

Summary Hairy root cultures of strawberry (Fragaria x ananassa Duch.) were induced with the Agrobacterium rhizogenes strain A4. Cultures were maintained on B50 medium but could also grow on a minimal medium, which did not inhibit the growth of arbuscular mycorrhizal fungi. The growth and nutrient uptake were characterized in shake flasks and in a bioreactor. Spores of the native Finnish arbuscular mycorrhizal fungus Glomus fistulosum V128 were used to infect strawberry (Fragaria x ananassa Duch. Senga Sengana) hairy roots in vitro. During cultivation, vegetative spore formation was observed. At the end of the cultivation, hyphae and arbuscules were observed in the stained roots.Abbreviations AM arbuscular mycorrhiza - AMF arbuscular mycorrhizal fungus     

Screening and selection of a microbial lipase for the stereospecific hydrolysis of Verlukast

Summary A search was implemented for a microbial lipase capable of bioconverting a diester (dimethyl 5-(3-(2-(7-chloroquinolin-2-yl)ethyl)phenyl)4,6-dithianon to its S-ester acid, an intermediate in the production of Verlukast (a leukotriene receptor antagonist). Required properties of the sought-after enzyme included a high enantiomeric selectivity (e.e. >98%), the formation of only trace amounts of diacid and a high bioconversion rate. This search yielded 57 lipase-producing microorganisms, 18 of which presented detectable bioconversion activity. Thirteen of these microbes were selected for further study based upon their lipase production level and enzyme stability at harvest. Despite their common enzymatic property, namely the hydrolysis of triglycerides, these lipase preparations presented diverse ester acid specific synthesis rates (from <0.01 g/unit/h to 0.98 g/unit/h) and diacid formation levels (from 0% to 35%). One of these microbes, identified asPseudomonas aeruginosa (strain MB 5001), was found to produce a lipase having all of the above-listed required properties. The initial fermentation process developed in shake flasks was rapidly and successfully scaled up in 23-liter labora bioreactors, achieving a maximum production of 35 units/ml of lipase after 48 h of cultivation.     

Fermentation of Detoxified Acid-Hydrolyzed Pyrolytic Anhydrosugars into Bioethanol with <Emphasis Type="Italic">Saccharomyces cerevisiae</Emphasis> 2.399

Pyrolysate obtained from the pyrolysis of waste cotton is a source of fermentable sugars that could be fermented into bioethanol fuel and other chemicals via microbial fermentation. However, pyrolysate is a complex mixture of fermentable and non-fermentable substrates causing inhibition of the microbial growth. The aim of this study was to detoxify the hydrolysate and then ferment it into bio-ethanol fuel in shake flasks and fermenter applying yeast strain Saccharomyces cerevisiae 2.399. Pyrolysate was hydrolyzed to glucose with 0.2 M sulfuric acid, neutralized with Ba(OH)₂ followed by treatment with ethyl acetate and activated carbon to remove fermentation inhibitors. The effect of various fermentation parameters such as inoculum concentration, pH and hydrolysate glucose was evaluated in shake flasks for optimum ethanol fermentation. With respect to inoculum concentration, 20% v/v inoculum i.e. 8.0 × 10⁸–1.2 × 10⁹ cells/mL was the optimum level for producing 8.62 ± 0.33 g/L ethanol at 9 h of fermentation with a maximum yield of 0.46 g ethanol/g glucose. The optimum pH for hydrolysate glucose fermentation was found to be 6.0 that produced 8.57 ± 0.66 g/L ethanol. Maximum ethanol concentration, 14.78 g/L was obtained for 4% hydrolysate glucose concentration after 16 h of fermentation. Scale-up studies in stirred fermenter produced much higher productivity (1.32 g/L/h^–1) compared to shake flask fermentation (0.92 g/L/h^–1). The yield of ethanol reached a maximum of 91% and 89% of the theoretical yield of ethanol in shake flasks and fermenter, respectively. The complex of integrated models of development was applied, that has been successfully tested previously for the mathematical analysis of the fermentation processes.     

Enhanced production of l‐lactic acid by Lactobacillus thermophilus SRZ50 mutant generated by high‐linear energy transfer heavy ion mutagenesis

The aim of this study was to improve l ‐lactic acid production of Lactobacillus thermophilus SRZ50. For this purpose, high efficient heavy‐ion mutagenesis technique was performed using SRZ50 as the original strain. To enhance the screening efficiency for high yield l ‐lactic acid producers, a scale‐down from shake flask to microtiter plate was developed. The results showed that 24‐well U‐bottom MTPs could well alternate shake flasks for L. thermophilus cultivation as a scale‐down tool due to its a very good comparability to the shake flasks. Based on this microtiter plate screening method, two high l ‐lactic acid productivity mutants, A59 and A69, were successfully screened out, which presented, respectively, 15.8 and 16.2% higher productivities than that of the original strain. Based on fed‐batch fermentation, the A69 mutant can accumulate 114.2 g/L l ‐lactic acid at 96 h. Hence, the proposed traditional microbial breeding method with efficient high‐throughput screening assay was proved to be an appropriate strategy to obtain lactic acid‐overproducing strain.     

Key Process Conditions for Production of C4 Dicarboxylic Acids in Bioreactor Batch Cultures of an Engineered Saccharomyces cerevisiae Strain

A recent effort to improve malic acid production by Saccharomyces cerevisiae by means of metabolic engineering resulted in a strain that produced up to 59 g liter⁻¹ of malate at a yield of 0.42 mol (mol glucose)⁻¹ in calcium carbonate-buffered shake flask cultures. With shake flasks, process parameters that are important for scaling up this process cannot be controlled independently. In this study, growth and product formation by the engineered strain were studied in bioreactors in order to separately analyze the effects of pH, calcium, and carbon dioxide and oxygen availability. A near-neutral pH, which in shake flasks was achieved by adding CaCO₃, was required for efficient C₄ dicarboxylic acid production. Increased calcium concentrations, a side effect of CaCO₃ dissolution, had a small positive effect on malate formation. Carbon dioxide enrichment of the sparging gas (up to 15% [vol/vol]) improved production of both malate and succinate. At higher concentrations, succinate titers further increased, reaching 0.29 mol (mol glucose)⁻¹, whereas malate formation strongly decreased. Although fully aerobic conditions could be achieved, it was found that moderate oxygen limitation benefitted malate production. In conclusion, malic acid production with the engineered S. cerevisiae strain could be successfully transferred from shake flasks to 1-liter batch bioreactors by simultaneous optimization of four process parameters (pH and concentrations of CO₂, calcium, and O₂). Under optimized conditions, a malate yield of 0.48 ± 0.01 mol (mol glucose)⁻¹ was obtained in bioreactors, a 19% increase over yields in shake flask experiments.In recent years, biologically produced 1,4-dicarboxylic acids (succinate, malate, and fumarate) have attracted great interest as more sustainable replacements for oil-derived commodity chemicals, such as maleic anhydride (50). Malate is currently mainly produced via petrochemical routes for use in food and beverages (18). Development of a biotechnological production process started in the early 1960s with the investigation of the natural malate producer Aspergillus flavus (2). Although process improvements eventually resulted in high product yields and productivities (6), the potential production of aflatoxins (20) prevented the use of this filamentous fungus in industry. Other investigated natural malate-producing fungi (listed in reference 51) produced insufficient malate for industrial use. With the rational design options of metabolic engineering, microorganisms that do not naturally produce large amounts of malic acid may also be considered as production platforms. Wild-type Saccharomyces cerevisiae strains produce little if any malate but would be an interesting starting point for the construction of an efficient malate producer. This yeast has a relatively high tolerance to organic acids and low pH, and due to its role as a model organism in research, a well-developed metabolic engineering toolbox is available. In addition, wild-type S. cerevisiae strains have GRAS (Generally Regarded As Safe) status, so that modified strains are more likely to be allowed in the production of food-grade malic acid.One of the main challenges in the development of an organic acid-producing strain of S. cerevisiae has been the elimination of ethanol formation, which in wild-type strains occurs even under aerobic conditions when glucose concentrations are high (45). Deletion of the pyruvate decarboxylase-encoding genes was found to prevent ethanolic fermentation (17). After evolutionary engineering to remove the growth defects usually associated with pyruvate decarboxylase-negative S. cerevisiae strains, a strain was obtained that produced large amounts of pyruvate, a direct precursor to malate, when grown on glucose (42). Subsequent overexpression of the anaplerotic enzyme pyruvate carboxylase, a cytosolically relocalized malate dehydrogenase and a heterologous malate transporter from Schizosaccharomyces pombe led to a strain that produced significant amounts of malate (51). Cultivation in calcium carbonate (CaCO₃)-buffered shake flasks resulted in malate titers of up to 59 g liter⁻¹ at a yield of 0.42 mol (mol glucose)⁻¹.There are many differences between cultivation in shake flasks and cultivation in (laboratory or industrial) bioreactors. As shake flask cultures lack online pH monitoring and control, there is often significant pH variation over time. The pH is of particular importance. If the yeast can be persuaded to produce organic acids at lower pH values, this reduces the need for active neutralization and thereby reduces by-product formation such as gypsum. However, thermodynamic constraints on acid export, as well as increased stress levels from (undissociated) acid and the low pH, often limit the ability of the microorganisms to produce acids at low pH (32, 43). For this reason, the poorly soluble compound CaCO₃ has traditionally been used to maintain a near-neutral pH in malic acid-producing microbial cultures (6, 29, 51). Adding CaCO₃ also gives increased concentrations of bicarbonate (and thereby CO₂), a substrate for pyruvate carboxylase in the carboxylation of pyruvate (a C₃ carbon molecule) to oxaloacetate (C₄ carbon), as well as calcium. Calcium is known to be involved in cellular signaling pathways (22, 26, 33, 46) and to influence pyruvate carboxylase activity (21, 24). Finally, oxygen transfer rates in shake flasks are often poor compared to those in stirred (laboratory) bioreactors. The formation of significant concentrations (25 g liter⁻¹) of glycerol, a well-known redox sink in S. cerevisiae (41), in shake flask cultures of the engineered malate-producing strain (51) was a strong indication of oxygen limitation.Initial experiments in aerobic, pH-controlled bioreactor cultures of the malate- and succinate-producing Saccharomyces cerevisiae strain RWB525 yielded only low concentrations of these C₄ dicarboxylic acids. The goal of the present study was to identify process parameters that explain the different production levels in shake flask and bioreactor cultures. To this end, we analyzed, both separately and in combination, the impact of culture pH and concentrations of calcium, carbon dioxide, and oxygen on the production of malate and succinate.     

Influence of acetate on the growth of recombinant Escherichia coli JM103 and product formation

The influence of the acetate addeed to the M9 minimal medium and to the Luria-Bertani medium without and with glucose supplement on the growth of recombinant Escherichia coli J103 with three different types of multicopy plasmids and on the production of the fusion protein SpA :: EcoRI were investigated in shake flasks without and with induction of the gene expression by a temperature shift from 30 °C to 42 °C. At the beginning of the induction of gene expression concentrated LB-medium was added to the shake flask. Without this supplement of M9 medium no gene expression occurred.List of Symbols LB Luria Bertani cultivation medium (Table 2) - M9 cultivation medium (Table 1) - P enzym activity [U ml^–1] - te]TCC total cell count [10⁶ cells ml^–1] - specific growth rate [h-1]     

Interaction of cultural conditions and end-product distribution in Bacillus subtilis grown in shake flasks

Summary A culture of Bacillus subtilis, in which the relative production of acetoin (Ac) and butanediol (Bu) is highly sensitive to oxygen tension as well as to mixing conditions, was used to evaluate several culture conditions in 500-ml shake flasks. The concentration ratio of these metabolites (Ac/Bu) produced in a defined period of culture time was used as a parameter for comparative purposes. The influence of working volume, shaking speed, broth viscosity and the presence of baffles were evaluated. Using unbaffled flasks it was found that working volume had the most influence on oxygenation in shake flasks, especially below 10%, where differences in Ac/Bu ratios up to ten times could be measured. Shaking speed played an important role only at values higher than 400 rpm or when small working volumes were used. The addition of xanthan gum decreased the Ac/Bu ratio nearly four times under equivalent working conditions and also diminished the influence of shaking speed. In general, Ac/Bu was higher when sulphite oxygen transfer rate (OTR) values were higher. However, the test culture was able to detect differences which were not evident using the OTR method. Comparing Ac/Bu ratios in stirred fermentors from the literature, it seems that similar oxygenation conditions can be reached in non-baffled shake flasks only at very high shaking speeds using small working volumes. With baffled flasks, our data suggest that better oxygenation and mixing can be achieved in shake flasks if compared with those obtained in stirred fermentors at conventional power inputs.     

A novel strain of Streptomyces malaysiensis isolated from Brazilian soil produces high endo-β-1,4-xylanase titres

One hundred and sixty two actinomycete strains isolated from Brazilian soils were screened for xylanase activity, according to the size of the hydrolysis zones observed in oat spelts xylan agar plates. The strain AMT-3, later identified as Streptomyces malaysiensis, was selected as the best producer. In subsequent shake flasks fermentations using growth media contanning 1% (w/v) of either birchwood, or oat spelts xylan, plus organic nitrogen and salts, high endo--1,4-xylanase titres (EC 3.2.1.8) (116 U ml^–1) were observed in the larchwood medium within 6 days. This is the first report concerning xylanase production by streptomyces malaysiensis, which has been recently described as a new species.     

High-throughput system for screening of high <Emphasis Type="SmallCaps">l</Emphasis>-lactic acid-productivity strains in deep-well microtiter plates

For strain improvement, robust and scalable high-throughput cultivation systems as well as simple and rapid high-throughput detection methods are crucial. However, most of the screening methods for lactic acid bacteria (LAB) strains were conducted in shake flasks and detected by high-performance liquid chromatography (HPLC), making the screening program laborious, time-consuming and costly. In this study, an integrated strategy for high-throughput screening of high l-lactic acid-productivity strains by Bacillus coagulans in deep-well microtiter plates (MTPs) was developed. The good agreement of fermentation results obtained in the MTPs platform with shake flasks confirmed that 24-well U-bottom MTPs could well alternate shake flasks for cell cultivation as a scale-down tool. The high-throughput pH indicator (bromocresol green) and l-lactate oxidase (LOD) assays were subsequently developed to qualitatively and quantitatively analyze l-lactic acid concentration. Together with the color halos method, the pH indicator assay and LOD assay, the newly developed three-step screening strategy has greatly accelerated the screening process for LAB strains with low cost. As a result, two high l-lactic acid-productivity mutants, IH6 and IIIB5, were successfully screened out, which presented, respectively, 42.75 and 46.10 % higher productivities than that of the parent strain in a 5-L bioreactor.     

The use of lignocellulosic wastes for production of cellulase by Trichoderma reesei

Summary The feasibility of cellulase production by Trichoderma reesei using inexpensive lignocellulosic material was examined. Sulfite pulp used as standard substrate yielded 3.7 IU/ml filter paper units (FPU) and 2.15 IU/ml -glucosidase. The yield was 185 FPU per gram total carbohydrate (CH) in the fermentation medium. Steam treated wheat straw (2%) gave 1.9 FPU/ml, 0.83 IU/ml -glucosidase and 151 FPU/g CH, whereas the spent fibres remaining after enzymatic hydrolysis of steamed wheat straw gave 2.4 FPU/ml, 1.55 IU/ml -glucosidase and 147 FPU/g CH. A good substrate (3%) was also the combustible fraction of municipal waste (BRAM) treated with NaOH, which gave 2.5 FPU/ml, 0.86 IU/ml -glucosidase and 130 FPU/g CH. A further increase in the final enzyme titer is obtainable by increasing the substrate concentration. In shake cultures 5% steamed wheat straw gave 3.8 FPU/ml and 1.95 IU/ml -glucosidase. Untreated wheat straw gave only low final enzyme titers and low yields of FPU/g CH. In the case of lignocellulosic substrates a constant pH-value of pH 6.0 during the fermentation gave optimal yields.