Biocatalytic processes for the production of fatty acid esters

A comparative study of the oleyl oleate production using conventional and enzymatic catalysts has been carried out. The present paper describes the flow diagrams for these processes and compares operation conditions for batch reaction and the downstream proceedings. In addition, continuous and batch processes have been studied. In order to compare the different processes three major points are considered: product properties improvements, operation improvements and improvements on safer and environmental aspects. Experience has shown that biocatalyst is in favour only when most of these issues are far positive for biocatalyst. Enzymatic catalysts involve simpler processes carried out under milder reaction conditions.     

Process design and economic studies of alternative fermentation methods for the production of ethanol

Cell recycle and vacuum fermentation processes are described for the continuous production of ethanol. Preliminary process design studies are employed to make an economic comparison of these alternative fermentation schemes with continuous and batch fermentation technologies. Designs are based on a production capacity of 78,000 gal 95% ethanol (EtOH)/day employing molasses as the fermentation substrate. The studies indicate that a 57% reduction in fixed capital investment is realized by continuous rather than batch operation. Further decreases in required capital investment of 68 and 71% over batch fermentation were obtained for cell recycle and vacuum operation, respectively. However, ethanol production costs were dominated by the cost of molasses, representing over 75% of the total manufacturing cost. But, when a reasonable yeast by-product credit was assumed, the net production cost for 95% ethanol was estimated at 82.3 and 80.6 cent/gal, for the cell recycle and vacuum processes, respectively.     

Operational concept for the improved synthesis of (R)-3,3'-furoin and related hydrophobic compounds with benzaldehyde lyase

Biphasic reaction systems for enzyme catalysis are an elegant way to overcome limited solubility and stability of reactants and facilitate continuous processes. However, many synthetically useful enzymes are not stable in biphasic systems of water and organic solvent. The entrapment in polymer beads of polyvinyl alcohol has been shown to enable the stable operation of enzymes unstable in conventional biphasic reaction systems. We report the extension of this concept to continuous operation in a fluidised bed reactor. The enzyme benzaldehyde lyase was used for the continuous synthesis of enantiopure (R)-3,3'-furoin. The results show enhanced stability with half-life times under operation conditions of more than 100 h, as well as superior enzyme utilisation in terms of productivity. Furthermore, racemisation and oxidation of the product could be successfully prevented under the non-aqueous and inert reaction conditions.     

Periodic optimization of continuous microbial growth processes

Steady-state operation of continuous bioreactors is not necessarily the optimum type of operation. The method of pi-criterion is used in this work to determine whether periodic variation of the dilution rate can enhance the performance of continuous fermentation processes. It is found that the presence of time delay in the dynamic response of the chemostat renders a periodic operation of bioreactors, used for biomass production, superior to any steady-state operation. Also, employing Williams' structured model it is shown that cycling improves the average protein productivity.     

Process engineering in biological aerobic waste-water treatment

A non-comprehensive review of several technical developments in the field of aerobic biological waste-water treatment engineering is carried out, considering the active role the engineers have to play in this field. This paper brings together conventional and advanced problems in the field of aerobic biological waste-water treatment. Such an overview of biological waste-water treatment also precedes comments on some important aspects concerning the microorganisms responsible for waste-water treatment as well as considerations of the application of fundamentals and kinetics to the analysis of the biological processes used most commonly for aerobic biological waste-water treatment. A survey of the development of the biological activated-sludge process and some modifications are given. Some problems implied in the conventional activated-sludge waste-water treatment are analyzed, considering conventional processes and bioreactor models (the continuous stirred-tank reactor model and the plug-flow reactor models of the activated-sludge process) as well as aerated lagoons. Further, modifications of the activated-sludge process are presented. These include additional details on the bioreactor progress and applications, with emphasis on aspects concerning airlift bioreactors and their variants, deep-shaft bioreactors and reciprocating jet bioreactors which are considered as the third generation of bioreactors owing to their important advantages in design, operation and performance in waste-water treatment. Sequencing-batch reactors and aerobic digestion processes, including conventional aerobic digestion, high-purity oxygen digestion, thermophilic aerobic digestion and cryophylic aerobic digestion are also reviewed. Finally, some aspects regarding the operational factors that are involved in the selection of the reactor type are included.     

Modeling the Residence Time Distribution of Integrated Continuous Bioprocesses

In response to the biopharmaceutical industry advancing from traditional batch operation to continuous operation, the Food and Drug Administration (FDA) has published a draft for continuous integrated biomanufacturing. This draft outlines the most important rules for establishing continuous integration. One of these rules is a thorough understanding of mass flows in the process. A computer simulation framework is developed for modeling the residence time distribution (RTD) of integrated continuous downstream processes based on a unit‐by‐unit modeling approach in which unit operations are simulated one‐by‐one across the entire processing time, and then combined into an integrated RTD model. The framework allows for easy addition or replacement of new unit operations, as well as quick adjustment of process parameters during evaluation of the RTD model. With this RTD model, the start‐up phase to reach steady state can be accelerated, the effects of process disturbances at any stage of the process can be calculated, and virtual tracking of a section of the inlet material throughout the process is possible. A hypothetical biomanufacturing process for an antibody was chosen for showcasing the RTD modeling approach.     

Advanced model‐based control strategies for the intensification of upstream and downstream processing in mAb production

Current industrial trends encourage the development of sustainable, environmentally friendly processes with minimal energy and material consumption. In particular, the increasing market demand in biopharmaceutical industry and the tight regulations in product quality necessitate efficient operating procedures that guarantee products of high purity. In this direction, process intensification via continuous operation paves the way for the development of novel, eco‐friendly processes, characterized by higher productivity and lower production costs. This work focuses on the development of advanced control strategies for (i) a cell culture system in a bioreactor and (ii) a semicontinuous purification process. More specifically, we consider a fed‐batch culture of GS‐NS0 cells and the semicontinuous Multicolumn Countercurrent Solvent Gradient Purification (MCSGP) for the purification process. The controllers are designed following the PAROC framework/software platform and their capabilities are assessed in silico, against the process models. It is demonstrated that the proposed controllers efficiently manage to increase the system productivity, returning strategies that can lead to continuous, stable process operation. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:966–988, 2017     

Production of cell mass and pertussis toxin by Bordetella pertussis.

The cultivation of Bordetella pertussis affects production of pertussis toxin and biomass. Comparison of batch mode, chemostat operation and pHstat-turbidostatic control showed that productivities for the continuous process were greater than that for the batch operation. Continuous operation in balanced growth at the maximum specific growth rate, provided by the pHstat, resulted in the maximum specific production rate. Because of the strong association of pertussis toxin synthesis and cell growth, the concentration of toxin in the effluent of the continuous processes was greater than the maximum obtained in the batch bioprocess. An expanded Luedeking-Piret model of product formation kinetics fits the observed chemostat data and demonstrates that the production of pertussis toxin from the culture of B. pertussis is predominantly growth associated.     

Modelling for waste water treatment by Rhodopseudomonas palustris Y6 immobilized on fibre in a columnar bioreactor

A kinetic model of continuous treatment of waste water by Rhodopseudomonas palustris Y6 immobilized on soft fibre in a columnar bioreaction system was established. Good agreement was found between the model prediction and the experimental data from continuous operation [initial chemical oxygen demand (COD) concentration = 29.700 g/l] of the system. The optimum operational conditions for the maximum COD reduction capacity were investigated from the model prediction and the experimental data. The waste water treatment process may significantly increase the waste reduction capacity because a large amount of active biomass for COD reduction is immobilized in the system, resulting in operation stability. The results presented here provide a useful basis for further scaling up and efficient operation of waste water treatment processes.     

The fine structure of the ganglia of the guinea-pig trachea

Summary The parasympathetic ganglia of the guinea-pig trachea have been investigated by scanning and transmission electron microscopy. They are covered by a continuous perineurium and connective tissue is found between the neural elements. Blood vessels inside the ganglia have continuous endothelia and are sometimes accompanied by pericytes and a sheath of perineurial cells. Individual neuronal cell bodies and large processes are almost completely covered by a thin layer of satellite cells, except for very small areas that directly face the basal lamina and connective tissue space. Nerve fibres are also completely and individually ensheathed by Schwann cell processes; naked fibres are not found. In some regions of the nerve cell body, there are complex interdigitations between short neuronal processes and satellite cells. Large differences in the size of neurons may indicate the presence of different neuronal populations. Nerve endings containing mainly small clear vesicles are the most common type, and these form synapses on dendrites, but some profiles have many large granular vesicles. These ganglia resemble other parasympathetic, sympathetic and sensory ganglia and not the enteric ganglia. However, an unusual feature of the cytoplasm of the satellite and Schwann cells is the abundance of 10 nm intermediate filaments.     

Multistep reactions with immobilized microorganisms

This review presents some examples of new semicontinuous and continuous processes for product formation and for degradation of xenobiotics with immobilized microorganisms. A semicontinuous process for glycerol formation with Saccharomyces cerevisiae cells, adsorbed on sintered glass, and a continuous production of citric acid with Aspergillus niger, entrapped in calcium alginate, are given as examples of the production of primary metabolites. The production of ergot alkaloids with entrapped Claviceps purpurea demonstrates the possibilities of production of secondary metabolites. The continuous degradation of phenolic substances and that of 4-chlorophenol by entrapped and adsorbed microorganisms are given as examples of the possibility of a continuous degradation of xenobiotics by immobilized microorganisms. The continuous degradation of these substances was successful not only in artificial solutions but also in sterile and nonsterile wastewater.     

体内连续定向进化研究进展

定向进化为合成生物学的发展提供了一种简单高效的工具,尤其在化学品合成和医药开发方面发挥着重要的作用.但是传统的定向进化技术存在操作繁琐、耗时和效率低的问题,不能满足大量突变文库的构建和筛选.近几年,一项将突变、翻译(进化非基因)、筛选和复制过程进行无缝连接的体内连续定向进化技术开始出现,该技术在噬菌体、细菌和真核细胞中...     

Continuous desalting of refolded protein solution improves capturing in ion exchange chromatography: A seamless process

Truly continuous biomanufacturing processes enable an uninterrupted feed stream throughout the whole production without the need for holding tanks. We have utilized microporous anion and cation exchangers into which only salts, but not proteins, can penetrate into the pores for desalting of protein solutions, while diafiltration or dilution is usually employed for feed adjustments. Anion exchange and cation exchange chromatography columns were connected in series to remove both anions and cations. To increase operation performance, a continuous process was developed comprised of four columns. Continuous mode was achieved by staggered cycle operation, where one set of columns, consisting of one anion exchange and one cation exchange column, was loaded during the regeneration of the second set. Refolding, desalting and subsequent ion exchange capturing with a scFv as the model protein was demonstrated. The refolding solution was successfully desalted resulting in a consistent conductivity below 0.5 mS/cm from initial values of 10 to 11 mS/cm. With continuous operation process time could be reduced by 39% while productivity was increased to 163% compared to batch operation. Desalting of the protein solution resulted in up to 7‐fold higher binding capacities in the subsequent ion exchange capture step with conventional protein binding resins.     

How to Ignite an Atmospheric Pressure Microwave Plasma Torch without Any Additional Igniters

This movie shows how an atmospheric pressure plasma torch can be ignited by microwave power with no additional igniters. After ignition of the plasma, a stable and continuous operation of the plasma is possible and the plasma torch can be used for many different applications. On one hand, the hot (3,600 K gas temperature) plasma can be used for chemical processes and on the other hand the cold afterglow (temperatures down to almost RT) can be applied for surface processes. For example chemical syntheses are interesting volume processes. Here the microwave plasma torch can be used for the decomposition of waste gases which are harmful and contribute to the global warming but are needed as etching gases in growing industry sectors like the semiconductor branch. Another application is the dissociation of CO₂. Surplus electrical energy from renewable energy sources can be used to dissociate CO₂ to CO and O₂. The CO can be further processed to gaseous or liquid higher hydrocarbons thereby providing chemical storage of the energy, synthetic fuels or platform chemicals for the chemical industry. Applications of the afterglow of the plasma torch are the treatment of surfaces to increase the adhesion of lacquer, glue or paint, and the sterilization or decontamination of different kind of surfaces. The movie will explain how to ignite the plasma solely by microwave power without any additional igniters, e.g., electric sparks. The microwave plasma torch is based on a combination of two resonators — a coaxial one which provides the ignition of the plasma and a cylindrical one which guarantees a continuous and stable operation of the plasma after ignition. The plasma can be operated in a long microwave transparent tube for volume processes or shaped by orifices for surface treatment purposes.     

Modelling and simulation techniques for membrane biology

One of the most important aspects of Computational Cell Biology is the understanding of the complicated dynamical processes that take place on plasma membranes. These processes are often so complicated that purely temporal models cannot always adequately capture the dynamics. On the other hand, spatial models can have large computational overheads. In this article, we review some of these issues with respect to chemistry, membrane microdomains and anomalous diffusion and discuss how to select appropriate modelling and simulation paradigms based on some or all the following aspects: discrete, continuous, stochastic, delayed and complex spatial processes.     

Continuous counter‐current chromatography for capture and polishing steps in biopharmaceutical production

The economic advantages of continuous processing of biopharmaceuticals, which include smaller equipment and faster, efficient processes, have increased interest in this technology over the past decade. Continuous processes can also improve quality assurance and enable greater controllability, consistent with the quality initiatives of the FDA. Here, we discuss different continuous multi‐column chromatography processes. Differences in the capture and polishing steps result in two different types of continuous processes that employ counter‐current column movement. Continuous‐capture processes are associated with increased productivity per cycle and decreased buffer consumption, whereas the typical purity‐yield trade‐off of classical batch chromatography can be surmounted by continuous processes for polishing applications. In the context of continuous manufacturing, different but complementary chromatographic columns or devices are typically combined to improve overall process performance and avoid unnecessary product storage. In the following, these various processes, their performances compared with batch processing and resulting product quality are discussed based on a review of the literature. Based on various examples of applications, primarily monoclonal antibody production processes, conclusions are drawn about the future of these continuous‐manufacturing technologies.     

Multistage continuous countercurrent diafiltration for formulation of monoclonal antibodies

There is growing interest in the development of fully integrated and continuous biomanufacturing processes for the production of monoclonal antibody products. A recent study has demonstrated the feasibility of using a two-stage countercurrent diafiltration (DF) process for continuous product formulation, but this system did not provide sufficient levels of buffer exchange for most applications. The objective of this study was to design and test a three-stage countercurrent DF system that could achieve at least 99.9% buffer exchange over 24 hr of continuous operation. Experimental data were obtained using concentrated solutions of human immunoglobulin G as a model protein, with the extent of vitamin B₁₂ removal used to track the extent of DF. Pall Cadence™ inline concentrators with Delta 30 kD regenerated cellulose membranes were used in the three stages to achieve high conversion in a single pass. The three-stage system showed stable operation with >99.9% vitamin B₁₂ removal and a minimal increase in pressure over the full 24 hr. Modules were effectively cleaned using sodium hydroxide, with nearly complete recovery of water permeability. A simple economic analysis was presented that accounts for the trade-offs between quantity of buffer used and membrane costs for this type of countercurrent staged DF process. The results provide important insights to the design and operation of a continuous process for antibody formulation.     

Estimation of biological kinetic parameters from a continuous integrated ozonation-activated sludge system treating domestic wastewater

The feasibility of treating municipal wastewater by a combined ozone-activated sludge continuous flow system was studied. Lab-scale experiments of both single activated sludge and combined ozone-activated sludge processes were carried out to determine the kinetic coefficients of the biological stage. The results obtained indicated a clear improvement in the kinetic parameters of the aerobic oxidation when a pre-ozonation stage was applied. Particularly, COD removal and nitrification rates were highly increased. The biokinetic parameters were also used to simulate and optimize the continuous reaction system. From the model prediction it was concluded that the integrated process (i.e., ozone-ASP) may significantly increase the waste reduction capacity. The results presented here provide a useful basis for further scaling up and efficient operation of ozone-ASP units in wastewater treatment processes.     

Controlled release of nutrients to mammalian cells cultured in shake flasks

Though cell culture-based protein production processes are rarely carried out under batch mode of operation, cell line and initial process development operations are usually carried out in batch mode due to simplicity of operation in widely used scale down platforms like shake flasks. Nutrient feeding, if performed, is achieved by bolus addition of concentrated feed solution at different intervals, which leads to large transient increases in nutrient concentrations. One negative consequence is increased waste metabolite production. We have developed a hydrogel-based nutrient delivery system for continuous feeding of nutrients in scale down models like shake flasks without the need for manual feed additions or any additional infrastructure. Continuous delivery also enables maintaining nutrient concentrations at low levels, if desired. The authors demonstrate the use of these systems for continuous feeding of glucose and protein hydrolysate to a suspension Chinese Hamster Ovary (CHO) culture in a shake flask. Glucose feeding achieved using the glucose-loaded hydrogel resulted in a 23% higher integral viable cell density and an 89% lower lactate concentration at the end of the culture when compared with a bolus-feed of glucose.     

Some myths and messages concerning the batch and continuous culture of animal cells

lt is often assumed that continuous processes are more difficult and less productive than a suite of batch processes for the production of a particular biomolecule. This paper cites two papers which have appeared in the literature which propound this view and examines in detaü the justification for the support of this contention. After reviewing those features where it is alleged that continuous processes are at a disadvantage, the authors of this paper conclude that the opposite is the case and that for suitable processes the most effective way of generating product is by the use of fully continuous processes. The choice of a particular process dependends on a variety of fixed and variable factors which are unique to the process. These factors are discussed and two decision trees are presented which are designed to facilitate the choice of the appropriate process technology. This revised version was published online in July 2006 with corrections to the Cover Date.