Process development of a recombinant antibody/interleukin-2 fusion protein expressed in protein-free medium by BHK cells

The production, purification and stability of quality (in terms of integrity and glycosylation) of an antibody/interleukin-2 fusion protein with potential application in tumour-targeted therapy expressed in BHK21 cells are described. Consistency of the product throughout time was determined by analysis of glycosylation of the fusion protein using MALDI-TOF mass spectroscopy and HPAEC-PAD combined with product integrity studies by SDS-PAGE and Western blotting. These investigations showed consistent expression in terms of integrity and of three major oligosaccharide structures of the fusion protein after 62 generations. The data obtained at this stage indicated the suitability of the cell line for production purposes. Different approaches for the production of this protein were subsequently carried out. The relative productivity of the recombinant fusion protein and general performance of the cells in two different protein-free medium (PFM) culture systems, continuous chemostat and continuous perfusion using a Centritech centrifuge as a cell retention device, were studied. The results indicate that the chemostat culture resulted in more stable and controllable nutrient environment, which could indicate better product consistency, in accordance with what has been observed under serum-containing conditions, in relation to the perfusion culture. Finally, product obtained from the chemostat culture was analysed and purified. The purification process was optimised with an increase in the overall yield from 38 to 70% being obtained, a significant improvement with important consequences for the implementation of an industrial-scale culture system. In conclusion, it was possible to produce and purify the recombinant antibody/interleukin-2 fusion protein assuring the quality and stability of the product in terms of integrity and glycosylation. Therefore, a candidate production process was established.     

Adaptation of BHK cells producing a recombinant protein to serum-free media and protein-free medium

In this work a recombinant BHK21 clone producing a fusion protein with potential application in tumour target therapy was adapted to five different serum-free media (SFM) and to a protein-free medium (PFM). Only the PFM did not require a gradual adaptation to cell growth in the absence of serum. All tested SFM required a gradual adaptation (up to 35 days). For the majority of the SFM tested, cell specific productivity was not affected by the decrease in serum concentration during adaptation; however, cell growth was significantly affected by the serum decrease. Both cell growth and productivity were increased when PFM SMIF6 was used instead of the control medium. Long term measurements (approximately 100 days) of cell specific productivity for PFM and the two best SFM showed that productivity was maintained. This indicates the media capability to be used in long term production processes.     

Production and purification of human menin from Drosophila melanogaster S2 cells using stirred tank reactor

A process was developed for producing human menin from transformed Drosophila Schneider 2 cells. Protein expression was achieved after inducing the metallothionein promoter by adding copper sulfate to cells growing in suspension in a stirred-tank reactor. Experiments in shake flasks showed that the production of menin was improved when the induction was conducted late in the exponential phase of cell growth at a concentration of 1–2 × 10⁷ cells ml^-1, with a copper concentration of 0.2 mM for no more than 24 h. This observation was confirmed by experiments in bench-scale fermentors. Subsequently, a pilot-scale fermentation yielded 1 mg l^-1 culture of purified menin. This revised version was published online in July 2006 with corrections to the Cover Date.     

Influence of medium composition on penicillin V production in a stirred tank reactor.

Penicillin production with a high-producing strain Penicillium chrysogenum was investigated under well-controlled conditions in a stirred tank reactor with complex media containing lard oil and lactose on the one hand, and lactose on the other hand. With lard oil, cell growth and product formation rates were higher, and the production time was shorter by 40 h than without lard oil. On account of the longer production time without lard oil, the amount of beta-lactam compounds was higher (29.93 g l-1), but the mole fraction of the decomposed products (penicilloic acid and penilloic acid) was larger (0.282) than the amount of penicillin V (23.25 g l-1) and the decomposed mole fraction (0.0747) with lard oil. The final product concentrations were about the same (20.86 g l-1 or 35,462 IU ml-1 with lard oil, and 20.43 g l-1 or 34510 IU ml-1 without lard oil). The mole fractions of the by-product (p-OH-penicillin V) were 0.0365 and 0.066. The substitution of lard oil with lactose is possible without a considerable reduction of process performance.     

Production of glutamine by micro-gel bead-immobilized Corynebacterium glutamicum 9703-T cells in a stirred tank reactor

The effectiveness of using micro-gel bead-immobilized cells for aerobic processes was investigated. Glutamine production by Corynebacterium glutamicum, 9703-T, cells was used as an example. The cells were immobilized in Sr-alginate micro-gel beads 500 m in diameter and used for fermentation processes in a stirred tank reactor with a modified impeller at 400 min^–1. Continuous production of glutamine was carried out for more than 220 h in this reactor and no gel breakage was observed. As a result of the high oxygen transfer capacity of this system, the glutamine yield from glucose was more than three times higher, while the organic acid accumulation was more than 24 times lower than those obtained with 3.0 mm-gel bead-immobilized cells in an airlift fermentor under similar experimental conditions. During the continuous fermentations there was evolution and proliferation of non-glutamine producing strains which led to a gradual decrease in the productivity of the systems. Although a modified production medium which suppresses cell growth during the production phase was effective in maintaining the productivity, the stability of the whole system was shortened due to high cell deactivation rate in such a medium.List of Symbols C kg/m³ glutamine concentration - C _A mol/m ³ local oxygen concentration inside the gel beads - C _AS mol/m ³ oxygen concentration at the surface of the gel beads - De m²/h effective diffusion coefficient of oxygen in the gel bead - DO mol/m³ dissolved oxygen concentration - F dm³/h medium flow rate - K h^–1 glutamine decomposition rate constant - Km mol/m³ Michaelis Menten constant - QO _2max mol/(kg · h) maximum specific respiration rate - R m radius of the gel beads - r m radial distance - t h time - V _C dm ³ volume of the gel beads - V _L dm ³ liquid volume in the reactor - Vm mol/(m³ · h) maximum respiration rate - X kg/m³ cell concentration - x r/R - y C _A /C_AS - h^–1 cell deactivation rate constant - Thiele modulus defined by R(Vm/De Km) ^1/2 - C _AS /Km - _C kg/(m³-gel · h) specific glutamine formation rate - _c dm³-gel/dm³ V _C /V _L      

Production of alkaline serine protease subtilisin Carlsberg by Bacillus licheniformis on complex medium in a stirred tank reactor

Bacillus licheniformis (DSM 641) was cultivated on complex medium in batch and fed-batch operations in a 20-l working volume stirred tank reactor. The medium composition (maltose, glucose, sucrose, fructose, ammonia, phosphate) and O₂ and CO₂ in the off-gas were monitored on-line; pH, pO₂, turbidity, culture fluorescence were monitored in situ; optical density, concentrations of sugars, amino acids, phosphate, proteins, DNA, protease activity and total solids content were monitored off-line. Problems of on-line sampling, cell concentration monitoring, and culture fluorescence measurements and the influence of medium components on the enzyme productivity are discussed. Close relationships between variations of pH, pO₂, O₂ transfer rate and CO₂ production rate on the one hand and cell mass and fluorescence intensity on the other were demonstrated in batch and in fed-batch cultures. Using suitable cultivation conditions, alkaline protease with high volume activity [15300 units (U)/ml] and specific activity (510 U/mg) was produced. By replacing the complex medium with a semisynthetic one, the volumetric activity was reduced by a factor of ten (to 1650 U/ml), but the specific productivity by a factor of only two (to 210 U/ml). Correspondence to: K. Schügerl     

Production of human immunodeficiency virus by chronically infected cells grown in protein-free medium.

A human T cell line chronically infected with Human Immunodeficiency Virus (HIV) has been adapted to grow in a chemically defined, protein-free medium. Virus particles are produced at rates comparable to those of serum-supplemented cultures; virus preparations free of undesirable proteins can be produced in preparative amounts by simple ultrafiltration procedures and cell culture supernatants can be used as such for the preparation of ELISA solid phases. This material has been used very conveniently for studies concerning characterization of antibodies against HlV-specific proteins, interaction of HIV with complement components and inclusion of human cell-derived proteins into virions; we propose its use as a powerful tool for the structural as well as functional analysis of the virus particle itself.     

Comparison of a production process in a membrane-aerated stirred tank and up to 1000-L airlift bioreactors using BHK-21 cells and chemically defined protein-free medium

The applicability of a protein-free medium for the production of recombinant human interleukin-2 with baby hamster kidney cells in airlift bioreactors was investigated. For this purpose, a BHK-21 cell line, adapted to grow and produce in protein-free SMIF7 medium without forming spheroids in membrane-aerated bubble-free bioreactors, was used as the producer cell line. First, cultivation of the cells was established at a 20-L scale using an internal loop airlift bioreactor system. During the culturing process the medium formulation was optimized according to the specific requirements associated with cultivation of mammalian cells under protein-free conditions in a bubble-aerated system. The effects of the addition of an antifoam agent on growth, viability, productivity, metabolic rates, and release of lactate dehydrogenase were investigated. Although it was possible to establish cultivation and production at a 20-L scale without the use of antifoaming substances, the addition of 0.002% silicon-oil-based antifoaming reagent improved the cultivation system by completely preventing foam formation. This reduced the release of lactate dehydrogenase activity to the level found in bubble-free aerated stirred tank membrane bioreactors and led to a reduction in generation doubling times by about 5 h (17%). Using the optimized medium formulation, cells were cultivated at a 1000-L scale, resulting in a culture performance comparable to the 20-L airlift bioreactor. For comparison, cultivations with protein-containing SMIF7 medium were carried out at 20- and 1000-L scales. The application of protein supplements did not lead to a significant improvement in the cultivation conditions. The results were also compared with experiments performed in a bubble-free aerated stirred tank membrane bioreactor to evaluate the influence of bubbles on the investigated culture parameters. The data implied a higher metabolic activity of the cells in airlift bioreactors with a 150% higher glucose consumption rate. The results of this study clearly demonstrate the applicability of a protein-free chemically defined medium for the production of recombinant proteins with BHK cells in airlift bioreactors.     

Semi-continuous xylose-to-xylitol bioconversion by Ca-alginate entrapped yeast cells in a stirred tank reactor

Candida guilliermondii FTI 20037 cells were entrapped in Ca-alginate beads and used for xylose-to-xylitol bioconversions during five successive batches in a stirred tank reactor. Supplemented sugarcane bagasse hemicellulosic hydrolysate was used as the fermentation medium. The average volume of the Ca-alginate beads was reduced by about 30% after the 600 h taken to perform the five bioconversion cycles, thus demonstrating physical instability under the conditions prevailing in the reactor vessel. In spite of this, almost steady bioconversion rates and yields were observed along the repeated batches. In average values, a production of 51.6 g l(-1), a productivity of 0.43 g l(-1 )h(-1) and a yield of 0.71 g g(-1) were attained in each batch, variation coefficients being smaller than 10%.     

Production of ethanol by a stirred catalytic basket reactor with immobilized yeast cells

A stirred catalytic basket reactor with immobilized yeast cells was used for the batchwise production of ethanol. Fractional conversions up to 0.99 in 10 h were attained, depending on the agitation rates, initial glucose, and cell densities. The volumetric productivity of the reactor was considerably better than that of conventional stirred tank reactors. Productivities were strongly dependent on the stirred speed.     

Evidence of oxygen limitation in a hollow fibre reactor with immobilized E. coli

Summary A hollow fibre reactor (HFR) has been used to immobilize a regulatory mutant ofE. coli to produce phenylalanine. Fermentation performance in the HFR using both air and pure oxygen shows evidence of significant oxygen limitation. In particular, levels of volatile fatty acids (VFA) produced served as an indication of oxygen limitation.     

Study of microencapsulated urease in a continuous feed,stirred tank reactor

Urease, (urea amidohydrolase, EC 3.5.1.5) co-encapsulated with haemoglobin in cellulose nitrate membranes was found to exhibit apparent Michaelis-Menten kinetics; however, a steadily increasing apparent Michaelis-Menten constant over the lifetime of the preparation was observed. The activity of the enzyme in a continuous feed stirred tank reactor (CSTR) was investigated and correlated with a mathematical model derived from basic Michaelis-Menten kinetics. Plots relating substrate conversion to feed substrate concentration and tank reactor capacity were constructed and found to be accurate to less than 15% error under the experimental conditions studied.     

Production of the biocontrol agent Pantoea agglomerans PBC-1 in a stirred tank reactor by batch and fed-batch cultures

Concerns about food safety as well as the development of resistance to many fungicides by major postharvest pathogens have increased recently. Biological control, using microorganisms antagonistic to the fungal plant pathogens, appears to be promising as an alternative to fungicides. The microbial biocontrol agent has to be produced on an industrial scale, maintaining its biocontrol efficacy. The purpose of the current study was to optimize the conditions for microbial biomass production of the biocontrol agent Pantoea agglomerans PBC-1 in a 2-l mechanically stirred reactor (STR), defining mixing and mass transfer technological parameters and the growth kinetics for different saccharides. In the batch mode, different impellers and spargers were tested. Despite the oxygen mass transfer improvement achieved with marine propeller combined with porous sparger, the biomass did not increase, if compared with the use of a Rushton turbine and L-sparger, pointing out the relevance of a radial flux for better broth homogenization. Different carbon sources were used: sucrose, glucose and fructose; each of which led to viable populations 3.9 × 10⁹, 1.4 × 10⁹, 3.9 × 10⁹ c.f.u/ml, respectively, after 20 h of incubation. Fed-batch technology allows the maintenance of high cell viability for longer periods of time in the stationary growth phase, which can be crucial for the scale-up of biocontrol agent production process that is achieved together with a reduction of 85% on the incidence caused by the pathogens, brought about by fresh microbial biomass preparation on artificially wounded apples or oranges, stored for 7 days at 25°C against Penicillium expansum and Penicillium digitatum.     

High-density culture of recombinant Chinese hamster ovary cells producing prothrombin in protein-free medium

A recombinant CHO cell line, CHO2DS, was immobilized on porous microcarrier Cytopore 1 and cultivated in 1 l modified Super-spinner and 2 l stirred tank bioreactor with the perfusion of a low-cost chemically defined protein-free medium DF6S. CHO2DS cells could enter into the inner space and grew both in the inner space and on the surface of Cytopore 1 in DF6S and produced prothrombin at 22 mg l^–1 after 10 days. From a seeding density of 5.7 × 10⁵ cells ml^–1, the highest viable cell density of CHO2DS was 1.12 × 10⁷ cells ml^–1.     

Growth of the malignant and nonmalignant human squamous cells in a protein-free defined medium

Summary A novel protein-free synthetic medium has been developed for the culture of human squamous cell carcinoma cells. This medium, designated PF86-1, supports the serial subcultivation of six out of nine human squamous cell carcinoma cell lines in a protein-free, chemically defined condition without the adapting culture from serum-containing conditions. These cell lines growing in PF86-1 exhibited nearly equal potency to grow in massive culture without noticeable changes in morphology but presented a significantly decreased level of colony forming efficiency when compared with the cells cultured in serum-containing media, suggesting the implication of some autocrine mechanism. Interestingly, this medium supported the growth of normal human squamous cells of oral mucosa and skin for more than 2 mo. in the primary explant culture in spite of high levels of calcium ion concentration, where the overgrowth of fibroblasts as contaminant was not observed. These results suggest that PF86-1 supports the growth of cells derived from epidermal tissues selectively and provides the same defined condition for growth of malignant and nonmalignant human squamous cells. It seems, therefore, that PF86-1 allows investigations on the products of squamous cell carcinoma cells or on the differences of growth mechanisms between normal and neoplastic human squamous cells.     

Biodiesel synthesis in a solvent-free system by recombinant Rhizopus oryzae: comparative study between a stirred tank and a packed-bed batch reactor

A simultaneous synthesis of biodiesel, as fatty acid methyl esters, and monoacylglycerols catalysed by the recombinant Rhizopus oryzae lipase immobilized by adsorption on Relizyme OD/403M is presented. The use of this 1(3)-positional specific lipase prevents the formation of glycerol as a by-product, thus avoiding its drawbacks. The synthesis was carried out in a solvent-free system and it has been studied in two different reactor systems: stirred tank and packed-bed reactor. Stirred tank reactor presented a high-initial reaction rate and achieved a 33.6% yield, which corresponds to a value of 50.4% of the maximum yield that can be achieved with a 1(3)-positional specific lipase. In packed-bed reactor there was a smaller initial reaction rate, but it was achieved a 49.1% yield, which corresponds to a 73.6% of the maximum yield. When a second batch is performed, the yield decreased only 4% when packed-bed reactor is employed whereas a drastic decrease is observed in a stirred tank operation. Therefore, packed-bed reactor showed a best performance and minor damage to the biocatalyst.     

A comparative study of immobilized amyloglucosidase in a packed bed reactor and a continuous feed stirred tank reactor

The catalytic activity of amyloglucosidase covalently attached to DEAE-cellulose was studied in a packed bed reactor and a continuous feed stirred tank reactor (CSTR) for the reaction maltose → glucose. At low flow rates mass-transfer limitations in the bed reactor lead to lower conversions for this reactor compared to the CSTR. Simple theoretical expressions for these reactors were compared with the experimental results. There are significant differences between the kinetic parameters and pH profile of the immobilized and free enzyme. The immobilized enzyme also showed greater stability at 50°C than did free amyloglucosidase. The temperature dependence of the reaction rate was the same for immobilized and free enzyme.