Growth rate control in fed-batch cultures of recombinant Saccharomyces cerevisiae producing hepatitis B surface antigen (HBsAg).

A recombinant Saccharomyces cerevisiae producing hepatitis B surface antigen (HBsAg) exhibited growth-associated product formation. By controlling the medium feed rate, based on the calculated amount of medium required for 1 h, a constant specific growth rate was obtained in the range of 0.12-0.18 h-1. In order to prolong the exponential growth phase, the medium feed rate was increased exponentially. A fed-batch cultivation method based on the production kinetics of batch culture enhanced HBsAg production ten times more than in batch culture. The reason for the increase can be explained by the fact that the production of HBsAg is expressed as an exponential function of time when the specific growth rate is controlled to a constant value in growth-associated product formation kinetics. In the scale-up of this culture to 91, the specific growth rate could also be maintained constant and the HBsAg production trend was similar to that in a 1-1 culture. However, ethanol accumulation occurred at a late stage in fed-bach culture. Ethanol produced was not reutilized and inhibited further cell growth.     

Reactor Design for the Novozym 435 ® -catalysed Enantioselective Esterification of 4-methyloctanoic Acid

The bench scale Novozym 435 ® catalysed esterification of 4-methyloctanoic acid with ethanol was studied at 35°C. Esterification in a batch reactor (molar ratio of 1:8 (acid:EtOH)) resulted in the isolation of the enantiomerically enriched product (ee p =81%) and substrate (ee s =93%). In order to integrate reaction and separation, liquid-vapour equilibria calculations were performed showing that an excess of ethanol results in a very low ester fraction in the vapour phase. Since this is undesirable for an integrated process of reaction and product removal, a repeated batch reaction was performed using a molar ratio of 10:1 (acid:EtOH). After six cycles (45% conversion) the ee of 4-methyloctanoic acid ethyl ester turned out to be 80%. For different E values the ee p was calculated for batch and repeated batch reactions. It was shown that in all cases the ee p was higher for the repeated batch reaction. However, the product is not enantiopure since the E value of the reaction is rather low at the low ethanol concentration used. An alternative approach would be the continuous separation of the product during the reaction. A mathematical model was developed to describe esterification in a packed bed reactor integrated with product separation. This model shows that integration of reaction and product removal in advance is not suitable either to obtain an enantiomerically pure product. Since the optimal reaction conditions (high ethanol concentration) and the optimal separation system (low ethanol concentration) do not match in this reaction, the preference is given to the batch reaction at high ethanol concentrations because in that case the highest enantioselectivity of the enzyme is obtained.     

Reactor Design for the Novozym 435 ® -catalysed Enantioselective Esterification of 4-methyloctanoic Acid

The bench scale Novozym 435 ® catalysed esterification of 4-methyloctanoic acid with ethanol was studied at 35°C. Esterification in a batch reactor (molar ratio of 1:8 (acid:EtOH)) resulted in the isolation of the enantiomerically enriched product (ee p =81%) and substrate (ee s =93%). In order to integrate reaction and separation, liquid-vapour equilibria calculations were performed showing that an excess of ethanol results in a very low ester fraction in the vapour phase. Since this is undesirable for an integrated process of reaction and product removal, a repeated batch reaction was performed using a molar ratio of 10:1 (acid:EtOH). After six cycles (45% conversion) the ee of 4-methyloctanoic acid ethyl ester turned out to be 80%. For different E values the ee p was calculated for batch and repeated batch reactions. It was shown that in all cases the ee p was higher for the repeated batch reaction. However, the product is not enantiopure since the E value of the reaction is rather low at the low ethanol concentration used. An alternative approach would be the continuous separation of the product during the reaction. A mathematical model was developed to describe esterification in a packed bed reactor integrated with product separation. This model shows that integration of reaction and product removal in advance is not suitable either to obtain an enantiomerically pure product. Since the optimal reaction conditions (high ethanol concentration) and the optimal separation system (low ethanol concentration) do not match in this reaction, the preference is given to the batch reaction at high ethanol concentrations because in that case the highest enantioselectivity of the enzyme is obtained.     

Continuous cultivation of recombinant Escherichia coli: Existence of an optimum dilution rate for maximum plasmid and gene product concentration

Growth yield factors, plasmid stability, cellular plasmid content, and cloned gene product activity for Escherichia coli HB101 containing plasmid pDM246 were measured at several dilution rates in continuous culture. Cell mass yield per mass of glucose consumed declined with increasing dilution rate. There was no evidence of plasmid segregational instability in any experiments, none of which employed selective medium. Plasmid content per cell varied with population-specific growth rate as observed in earlier batch experiments with the same strain. Plasmid content declined with increasing specific growth rate following indication of a maximum number of plasmids per cell at specific growth rates of ca. 0.3 h(-1). Cloned gene product (beta-lactamase) activity exhibited a sharp maximum with respect to dilution rate in continuous culture. Qualitatively different results were observed in previous experiments in batch cultivation in which specific growth rate changes were effected by altering medium composition.     

Biodesulphurization of coal: effect of pulse feeding and leachate recycle

Biodesulphurization of coal was carried out under four modes of operation namely: conventional batch, constant volume pulse feeding (CVPF), increasing volume pulse feeding (IVPF) and leachate recycle. The effects of different pulse feeding strategies and leachate (product) recycle on biological performance were studied and compared with a conventional batch process. The sulphur removal rates for each of the four processes were 0.04 g/day (batch), 0.09 g/day (CVPF), 0.19 g/day (IVPF) and 0.05 g/day (leachate recycle). The values of iron solubilization rate (batch-83 μg/ml/day; CVPF-136 μg/ml/day; IVPF-198 μg/ml/day; leachate recycle-133 μg/ml/day) also followed the same trend. The percentage sulphur removal on the 30th day using batch, CVPF, IVPF and leachate recycle processes was 72%, 93%, 97% and 90%, respectively. IVPF was found to be the best operational strategy for biodesulphurization process at enhanced rates for longer duration.     

Growth rate control in fed-batch cultures of recombinant Saccharomyces cerevisiae producing hepatitis B surface antigen (HBsAg)

Summary A recombinant Saccharomyces cerevisiae producing hepatitis B surface antigen (HBsAg) exhibited growth-assciated product formation. By controlling the medium feed rate, based on the calculated amount of medium required for 1 h, a constant specific growth rate was obtained in the range of 1.12-0.18 h^–1. In order to prolong the exponential growth phase, the medium feed rate was increased exponentially. A fedbatch cultivation method based on the production kinetics of batch culture enhanced HBsAg production ten times more than in batch culture. The reason for the increase can be explained by the fact that the production of HBsAg is expressed as an exponential function of time when the specific growth rate is controlled to a constant value in growth-associated product fromation kinetics. In the scale-up of this culture to 91, the specific growth rate could also be maintained constant and the HBsAg production trend was similar to that in a 1-l culture. However, ethanol accumulation occurred at a late stage in fed-bach culture. Ethanol produced was not reutilized and inhibited further cell growth. Offprint requests to: M. B. Gu     

Phase shifts in the stoichiometry of rifamycin B fermentation and correlation with the trends in the parameters measured online

Antibiotic fermentation processes are raw material cost intensive and the profitability is greatly dependent on the product yield per unit substrate consumed. In order to reduce costs, industrial processes use organic nitrogen substrates (ONS) such as corn steep liquor and yeast extract. Thus, although the stoichiometric analysis is the first logical step in process development, it is often difficult to achieve due to the ill-defined nature of the medium. Here, we present a black-box stoichiometric model for rifamycin B production via Amycolatopsis mediterranei S699 fermentation in complex multi-substrate medium. The stoichiometric coefficients have been experimentally evaluated for nine different media compositions. The ONS was quantified in terms of the amino acid content that it provides. Note that the black box stoichiometric model is an overall result of the metabolic reactions that occur during growth. Hence, the observed stoichiometric coefficients are liable to change during the batch cycle. To capture the shifts in stoichiometry, we carried out the stoichiometric analysis over short intervals of 8-16 h in a batch cycle of 100-200 h. An error analysis shows that there are no systematic errors in the measurements and that there are no unaccounted products in the process. The growth stoichiometry shows a shift from one substrate combination to another during the batch cycle. The shifts were observed to correlate well with the shifts in the trends of pH and exit carbon dioxide profiles. To exemplify, the ammonia uptake and nitrate uptake phases were marked by a decreasing pH trend and an increasing pH trend, respectively. Further, we find the product yield per unit carbon substrate to be greatly dependent on the nature of the nitrogen substrate. The analysis presented here can be readily applied to other fermentation systems that employ multi-substrate complex media.     

Batch culture kinetics of l-lactate fermentation employing Streptococcus sp. IO-1

We isolated a l-lactate producing cocci which grows at 37°C as the optimal temperature and pH of 7.0 that is capable of converting glucose to l-lactate with a conversion rate greater than 90%. No other stereochemical isomer of lactic acid was detected in the culture broth by enzymatic analysis. The fermentation exhibits typical end product inhibition and this was confirmed by culturing using medium to which 1% lactate was supplemented as the initial inhibitor. Numerical analysis of the cultures which were carried out at different initial sugar concentrations showed that the specific rates for growth, substrate consumption and lactate formation could be expressed using uncompetitive inhibition formulae. Using these equations, it may be possible to estimate the cell density, remaining sugar concentration and product formation at any phase of the batch fermentation without operation.     

Continuous production of cyclodextrins in an ultrafiltration membrane reactor,catalyzed by cyclodextrin glycosyltransferase from Bacillus circulans DF 9R

Cyclodextrins (CDs) are cyclic oligosaccharides of wide industrial application, whose synthesis is catalyzed by Cyclodextrin glycosyltransferase (CGTase) from starch. Here, CDs were produced using CGTase from Bacillus circulans DF 9R in continuous process and an ultrafiltration membrane reactor. The batch process was conducted as a control. This method allowed increasing the yield from 40 to 55.6% and the productivity from 26.1 to 99.5 mg of CD per unit of enzyme. The method also allowed obtaining a high‐purity product. The flow rate remained at 50% of its initial value after 24 h of process, improving the results described in the literature for starch hydrolysis processes. CGTase remained active throughout the process, which could be explained by the protective effect of the substrate and reaction products on CGTase stability. In addition, batch processes were developed using starches from different sources. We concluded that any of the starches studied could be used as substrate for CD production with similar yields and product specificity. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:695–699, 2015     

Daughter cells as an important factor in determining the physiological state of yeast populations

Cells of Candida utilis grown in a single-stage chemostat at D = 0.05, 0.1, 0.25, and 0.35 hr^?l were separated into a fraction of scar-bearing mother cells and a fraction of scar-free daughter cells. The scar-free cells were transferred into small batch cultures where the length of the maturation phase, changes in length and width of cells, specific growth rate, and specific rate of RNA and protein synthesis were examined for 5 hr. The daughter cells grown at D = 0.05 hr^?1 were very small at the moment of separation from the mother cells (about one-third of the mother cell). Their maturation phase (in a batch culture), at the beginning of which they attain the specific growth rate approaching the μ_max of the strain used, lasts for 3 hr. On the other hand, daughter cells grown at D = 0.35 hr^?1 are almost the same size as the mother cells at the moment of separation. After transfer to a batch culture they begin to bud almost immediately. Similarly, in their other morphological and physiological parameters they differ strikingly from immature daughter cells which are formed at low specific growth rates. The importance of these differences from the point of view of mathematical modeling of growth processes is discussed.     

Hybridoma growth and productivity: effects of conditioned medium and of inoculum size

Apart from gas concentrations, temperature, and pH, generally only the initial conditions can be manipulated in batch culture. Inoculum size and initial conditioned medium concentration represent two important considerations for optimal batch production. Two hybridoma cell lines were used to assess the impact of these initial conditions on population growth and monoclonal antibody productivity in suspension batch culture. Varying initial cell concentration over the range of 1.0 × 105 cells mL-1 to 3.0 × 105 cells mL-1 did not affect maximum product titre or maximum volumetric cell-hours attained. Initial percent of conditioned medium up to 40 percent strongly impacted on population growth and productivity, with initial levels of 30 to 40% conditioned medium reducing or eliminating lag phase and increasing average viable cell density. However, specific productivity and product titre declined with increasing initial percent conditioned medium, even on a per volume of fresh medium basis. Glutamine and glucose depletion or ammonia toxicity could cause depressed product titres when conditioned medium is used. Glutamine and glucose levels can easily be replenished in conditioned medium at minimal cost, and ammonia can be removed. Specific productivity was higher during cyclic batch operating mode than during batch operating mode. This may be because cyclic batch operating mode results in an incidental volume of conditioned medium at the beginning of each cycle. A two stage, cyclic-batch/batch operating mode can be employed to fully utilize medium and maximize product titre.     

Expression of joint moment in the joint coordinate system

The question of using the nonorthogonal joint coordinate system (JCS) to report joint moments has risen in the literature. However, the expression of joint moments in a nonorthogonal system is still confusing. The purpose of this paper is to present a method to express any 3D vector in a nonorthogonal coordinate system. The interpretation of these expressions in the JCS is clarified and an example for the 3D joint moment vector at the shoulder and the knee is given. A nonorthogonal projection method is proposed based on the mixed product. These nonorthogonal projections represent, for a 3D joint moment vector, the net mechanical action on the JCS axes. Considering the net mechanical action on each axis seems important in order to assess joint resistance in the JCS. The orthogonal projections of the same 3D joint moment vector on the JCS axes can be characterized as "motor torque." However, this interpretation is dependent on the chosen kinematic model. The nonorthogonal and orthogonal projections of shoulder joint moment during wheelchair propulsion and knee joint moment during walking were compared using root mean squares (rmss). rmss showed differences ranging from 6 N?m to 22.3 N?m between both projections at the shoulder, while differences ranged from 0.8 N?m to 3.0 N?m at the knee. Generally, orthogonal projections were of lower amplitudes than nonorthogonal projections at both joints. The orthogonal projection on the proximal or distal coordinates systems represents the net mechanical actions on each axis, which is not the case for the orthogonal projection (i.e., motor torque) on JCS axes. In order to represent the net action at the joint in a JCS, the nonorthogonal projection should be used.     

Maximizing interferon-gamma production by Chinese hamster ovary cells through temperature shift optimization: experimental and modeling

The Chinese hamster ovary (CHO) cell line producing interferon-gamma (IFN-gamma) exhibits a 2-fold increase in specific productivity when grown at 32 degrees C compared to 37 degrees C. Low temperature also causes growth arrest, meaning that the cell density is significantly lower at 32 degrees C, nutrients are consumed at a slower rate and the batch culture can be run for a longer period of time prior to the onset of cell death. At the end of the batch, product concentration is doubled at the low temperature. However, the batch time is nearly doubled as well, and this causes volumetric productivity to only marginally improve by using low temperature. One approach to alleviate the problem of slow growth at low temperature is to utilize a biphasic process, wherein cells are cultured at 37 degrees C for a period of time in order to obtain reasonably high cell density and then the temperature is shifted to 32 degrees C to achieve high specific productivity. Using this approach, it is hypothesized that IFN-gamma volumetric productivity would be maximized. We developed and validated a model for predicting the optimal point in time at which to shift the culture temperature from 37 degrees C to 32 degrees C. It was found that by shifting the temperature after 3 days of growth, the IFN-gamma volumetric productivity is increased by 40% compared to growth and production at 32 degrees C and by 90% compared to 37 degrees C, without any decrease in total production relative to culturing at 32 degrees C alone. The modeling framework presented here is applicable for optimizing controlled proliferation processes in general.     

Optimization of protein fusion partner length for maximizing in vitro translation of peptides

Using protein fusion partners for in vitro translation may increase solubility, assist in purification, or allow detection of small proteins and peptides. Here we show that the molar yield of peptide in a batch reaction may be maximized by optimizing the length of the translated product, which is composed of the fusion partner plus the peptide. Using truncated versions of GFP as a series of fusion partners, the molar yield increased approximately 3-fold as the length of the translated product was reduced from 250 to 100 amino acids. When the translated product was shortened below roughly 100 amino acids, molar yield fell as a result of proteolysis. This trend was verified using two fusion partners with different amino acid sequences. Furthermore, protease inhibitors were used to confirm that proteases were responsible for limiting accumulation of peptides below the optimal length.     

Improved performance with multiple fermentors for repeated batch cultivation for non-growth-associated products

Based on batch cultivation data for the production of L-glutamic acid from glucose, a comparative evaluation was made for repeated batch cultivations using one and more fermentors. The problem was formulated as maximizing the productivity of metabolic product with the specified conversion with respect to the cell age and the volume fraction used as seed for the subsequent repeated batch cultivation. Simulations were carried out with the assumption of no lag in product formation for the cases where the total operation time was specified as 200 h with reproducible batch cultivation cycles. The product production was assumed to be solely a function of product concentration. The computation results show the advantage of using more than one fermentor from the viewpoints of productivity and conversion, which will apply in general to non-growth-associated product production with delay time. In particular, three fermentors are recommended for the production of L-glutamic acid chosen as an example in this article.     

Perfusion seed cultures improve biopharmaceutical fed‐batch production capacity and product quality

Volumetric productivity and product quality are two key performance indicators for any biopharmaceutical cell culture process. In this work, we showed proof‐of‐concept for improving both through the use of alternating tangential flow perfusion seed cultures coupled with high‐seed fed‐batch production cultures. First, we optimized the perfusion N‐1 stage, the seed train bioreactor stage immediately prior to the production bioreactor stage, to minimize the consumption of perfusion media for one CHO cell line and then successfully applied the optimized perfusion process to a different CHO cell line. Exponential growth was observed throughout the N‐1 duration, reaching >40 × 10⁶ vc/mL at the end of the perfusion N‐1 stage. The cultures were subsequently split into high‐seed (10 × 10⁶ vc/mL) fed‐batch production cultures. This strategy significantly shortened the culture duration. The high‐seed fed‐batch production processes for cell lines A and B reached 5 g/L titer in 12 days, while their respective low‐seed processes reached the same titer in 17 days. The shortened production culture duration potentially generates a 30% increase in manufacturing capacity while yielding comparable product quality. When perfusion N‐1 and high‐seed fed‐batch production were applied to cell line C, higher levels of the active protein were obtained, compared to the low‐seed process. This, combined with correspondingly lower levels of the inactive species, can enhance the overall process yield for the active species. Using three different CHO cell lines, we showed that perfusion seed cultures can optimize capacity utilization and improve process efficiency by increasing volumetric productivity while maintaining or improving product quality. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 30:616–625, 2014     

The growth dynamics of a methanol-utilizing bacterium L3 in a batch bioreactor

The growth dynamics of a methanol utilizing bacterium, L3, in batch bioreactors were experimentally investigated. Formaldehyde, a key intermediate of methanol oxidation, is indicated to have a significant role in the complex batch growth behavior of L3. The intricate batch growth dynamics of many microorganisms can be elegantly characterized by examining the specific rates of exchange of nutrients and products between the cells and the cellular environment. Following such an analysis, the batch growth of L3 on methanol was characterized by the presence of unbalanced and balanced growth phases. The nature and significance of nutrient and product concentration profiles or semilog-arithmic profiles of nutrient and product exchange rates during balanced and unbalanced growth phases are also outlined.     

Gene‐expression‐based quality scores indicate optimal harvest point in Bordetella pertussis cultivation for vaccine production

The evolution of vaccine product quality during batch cultivation of Bordetella pertussis, the causative agent of whooping cough, was investigated with the goal to determine the optimal harvest point. The process was explored by measuring mRNA expression at frequent intervals during cultivation. The genes that are involved in virulence are already known for this product and changes in their expression levels are proposed to be indicative for product quality. A quantitative product quality score is calculated based on the expression levels of these virulence genes, which allows comparison of expected product quality between culture samples. Product quality scores were maximal throughout the logarithmic growth phase, but dropped significantly at the start of the stationary phase. This showed that the decreasing lactate and glutamate concentrations towards the end of the batch are critical for product quality. On‐line measurement of these nutrients allows the cultivation process to be harvested at the optimal harvest point, increasing process robustness and consistency. Biotechnol. Bioeng. 2009;103: 900–908. © 2009 Wiley Periodicals, Inc.     

A continuous multicolumn countercurrent solvent gradient purification (MCSGP) process

Biomolecules are often purified via solvent gradient batch chromatography. Typically suitable smooth linear solvent gradients are applied to obtain the separation between the desired component and hundreds of impurities. The desired product is usually intermediate between weakly and strongly adsorbing impurities, and therefore a central cut is required to get the desired pure product. The stationary phases used for preparative and industrial separations have a low efficiency due to strong axial dispersion and strong mass transfer resistances. Therefore a satisfactory purification often cannot be achieved in a single chromatographic step. For large scale productions and for very valuable molecules, countercurrent operation such as the well known SMB process, is needed in order to increase separation efficiency, yield and productivity. In this work a novel multicolumn solvent gradient purification process (MCSGP-process) is introduced, which combines two chromatographic separation techniques, which are solvent gradient batch and continuous countercurrent SMB. The process consists of several chromatographic columns, which are switched in position opposite to the flow direction. Most of the columns are equipped with a gradient pump to adjust the modifier concentration at the column inlet. Some columns are interconnected, so that non pure product streams are internally, countercurrently recycled. Other columns are short circuited and operate in batch mode. As a working example the purification of an industrial stream containing 46% of the hormone Calcitonin is considered. It is found that for the required purity the MCSGP unit achieves a yield close to 100% compared to a maximum value of a single column batch chromatography of 66%.     

Kinetics and modelling of an alcoholysis reaction catalyzed by cutinase immobilized on NaY zeolite

Fusarium solani pisi recombinant cutinase was immobilized by adsorption on NaY zeolite. The kinetics of the alcoholysis reaction of butyl acetate with hexanol in isooctane catalyzed by cutinase immobilized on NaY zeolite, was studied. The reaction kinetics is suggested to follow a Ping-Pong bi–bi mechanism in which competitive inhibition by excess of alcohols has been identified. No evidence of any significant external diffusional limitation has been detected. The time validation of the model was successfully achieved simultaneously for 15 experimental product evolutions in a batch stirred tank reactor (BSTR) for different initial reactant concentrations.