Monitoring of ethanol during fermentation of a lignocellulose hydrolysate by on-line microdialysis sampling, column liquid chromatography, and an alcohol biosensor

During a 70-h fermentation of a lignocellulose hydrolysate, the ethanol produced was monitored on-line using a microdialysis probe as an in situ sampling device. The dialysate components were then separated in a column liquid chromatographic system and the ethanol was selectively detected by an amperometric alcohol biosensor. The result was compared with two off-line analysis methods: one chromatographic method with refractive index (RI) detection and one enzymatic method based on spectrophotometric detection. The two methods base on enzymes were shown to give lower values than the chromatographic method based on RI detection, which is discussed n terms of selectivity. The investigated on-line setup was found to be a flexible system for monitoring of fermentations, allowing a sampling frequency of at least 12 h(-1) and with a delay between sampling and detection of less than 5 min. (c) 1994 John Wiley & Sons, Inc.     

On-line monitoring of monoclonal antibody formation in high density perfusion culture using FIA

An automated flow injection system for on-line analysis of proteins in real fermentation fluids was developed by combining the principles of stopped-flow, merging zones flow injection analysis (FIA) with antigen-antibody reactions. IgG in the sample reacted with its corresponding antibody (a-IgG) in the reagent solution. Formation of insoluble immunocomplexes resulted in an increase of the turbidity which was determined photometrically. This system was used to monitor monoclonal antibody production in high cell density perfusion culture of hybridoma cells. Perfusion was performed with a newly developed static filtration unit equipped with hydrophilic microporous tubular membranes. Different sampling devices were tested to obtain a cell-free sample stream for on-line product anlysis of high molecular weight (e.g., monoclonal antibodies) and low molecular weight (e.g., glucose, lactate) medium components. In fermentation fluids a good correlation (coefficient: 0.996) between the FIA method and an ELISA test was demonstrated. In a high density perfusion cultivation process mAb formation was succesfully monitored on-line over a period of 400 h using a reliable sampling system. Glucose and lactate were measured over the same period of time using a commercially available automatic analyser based on immobilized enzyme technology.Abbreviations TIA Turbidimetric immunoassay - mAb Monoclonal Antibody     

Gas chromatography and gateway sensors for on-line state estimation of complex fermentations (butanol-acetone fermentation)

A fermentation system has been designed to demonstrate the use of gas chromatography (GC) for on-line monitoring of the butanol-acetone and other complex saccharolytic fermentations. Tangential flow ultrafiltration was used to sterilely and continuously obtain a cell-free filtrate from the fermentation broth for on-line GC analysis of butanol, butyrate, acetate, acetone, ethanol, and acetoin. The liquid injection system consists of a phosphoric acid contactor, a slider-type injection valve, and a heater to address the difficulties (ghosting) encountered in the analysis of carboxylic acids. The fermentation headspace gas was also analyzed by on-line GC for nitrogen and carbon dioxide, while hydrogen was measured by difference. Raw chromatographic data were analyzed by a chromatography data system. Both raw and processed data were transmitted to a VAX 11/750 computer for further processing (using the fermentation equation) and archiving. The fermentation equation, which has recently been derived and tested on completed fermentation data, was also found to be valid during transient fermentations and thus useful as a gateway sensor for calculating various fermentation parameters on-line. Such parameters include glucose concentration and gas composition, as well as a number of unobservable parameters (such as Y(ATP), excess ATP, and NAD reduced by FdH(2)), which characterize the state of the fermentation.     

On-line monitoring and controlling system for fermentation processes

A personal computer-based on-line monitoring and controlling system was developed for the fermentation of microorganism. The on-line HPLC system for the analysis of glucose and ethanol in the fermentation broth was connected to the fermenter via an auto-sampling equipment, which could perform the pipetting, filtration and dilution of the sample and final injection onto the HPLC through automation based on a programmed procedure. The A/D and D/A interfaces were equipped in order to process the signals from electrodes and from the detector of HPLC, and to direct the feed pumps, the motor of stirrer and gas flow-rate controller. The software that supervised the control of the stirring speed, gas flow-rate, pH value, feed flow-rate of medium, and the on-line measurement of glucose and ethanol concentration was programmed by using Microsoft Visual Basic under Microsoft Windows. The signal for chromatographic peaks from on-line HPLC was well captured and processed using an RC filter and a smoothing algorithm. This monitoring and control system was demonstrated to be effective in the ethanol fermentation of Zymomonas mobilis operated in both batch and fed-batch modes. In addition to substrate and product concentrations determined by on-line HPLC, the biomass concentration in Z. mobilis fermentation could also be on-line estimated by using the pH control and an implemented software sensor. The substrate concentration profile in the fed-back fermentation followed well the set point profile due to the fed-back action of feed flow-rate control.     

A novel method for the on-line analysis of fermentation broth using a sampling device,microcentrifuge and HPLC

Summary This paper describes a novel system for on-line sampling and analysis of whole broth from a fermenter. The system comprises a steam sterilisable sampling device, high speed microcentrifuge and HPLC. We present results characterising the separation efficiency of the microcentrifuge under different conditions, and illustrate the system with glucose and acetate data from an Escherichia coli fermentation using the system. The on-line measurements have been confirmed by off-line analysis.     

Monitoring and control of methanol concentration during polysaccharide fermentation using an on-line methanol sensor

Combining principles of membrane separation and semiconductor gas sensor technology, we constructed a methanol sensor to follow methanol concentrations on-line. A length of silicone tubing allowed for mass transfer of methanol from the fermentation medium to a carrier gas which then flowed over a semiconductor gas sensor for detection. The sterilizable sensor demonstrated excellent ability in following methanol concentrations during the batch production of a polysaccharide by the organism Methylomonas mucosa, even as the fermentation broth became increasingly viscous. During fed-batch control by feeding methanol to the fermentation to maintain setpoint methanol levels, a drift in the sensor signal was noted and quantified. A drift factor was determined which, after it was incorporated into the calibration calculations, improved methanol concentration control greatly. Methanol concentration was held constant over a range of set point concentrations during fedbatch fermentations.     

On-line estimation of mycelial cell mass concentrations with a computer-interfaced filtration probe

This article deals with the design and operation of a filtration probe for estimating cell concentrations in fermentations involving mycelial organisms such as Penicillium chrysogenum. This device, a much improved version of one developed previously, is placed directly into the fermentor and measures the filtration properties of the fermentation broth, which are correlated to the cell concentration. The probe is connected to a computer system which enables on-line estimation of the cell concentration. Fiber-optic light guides are used in combination with a pair of light sources and receivers to detect the relative position of the filter-cake-fermentation-broth interface. The lower sensor in the filtration tube enables reliable estimation of cell mass upto about 20 g/L (dry wt), while the upper sensor yields useful measurement of the filtration properties upto a concentration of about 40 g/L (dry wt) and appears to have the potential to go even higher. Major advantages of this probe system are the ease of measurement and the on-line ability to measure very frequently, due to its nondestructive mode of operation. Thus, the probe obviates the need for manual sampling and reduces the risk of contaminating the culture. But, more significantly, it enables one to implement on-line schemes including feedback control.     

On-line monitoring of the viscosity in dextran fermentation using piezoelectric quartz crystal

A novel viscous sensor utilizing AT-cut quartz crystal to monitor the viscosity of fermentation broth was developed. The sensor system was constructed from the piezoelectric quartz crystal fixed to the cell, exposing only one side of the quartz crystal electrode, an oscillating circuit, a peak level meter, and a personal computer. In order to investigate the characteristics of the sensor system, a sensor signal relating to the resonant resistance of the quartz crystal was measured using dextran solutions with different molecular weights. The linear relationship was obtained between the sensor signal and the (rhoeta)(1/2) of the liquid, where rho and eta are the density and viscosity, respectively. The sensor signal was dependent not only on the viscosity of the liquid but also on the molecular weight of dextran, because dextran solution shows a non-Newtonian property. The sensor system was applied for the on-line monitoring of the viscosity in dextran fermentation. A good correlation was observed between the sensor signal and the viscosity value measured with a rotational viscometer for the fermentation broth. Little bubbling effect and agitation of the sensor signal were observed, showing that this system can be utilized for viscosity monitoring in a bioprocess.     

Computer-aided baker's yeast fermentations.

The economics of yeast production depend heavily upon the cellular yield coefficient on the carbon source and the volumetric productivity of the process. The application of an on-line computer to maximize these two terms during the fermentation requires a continuous method of measuring cell density and growth rate. Unfortunately, a direct sensor for biomass concentration suitable for use in industrial fermentations is not available. Material balancing, with the aid of on-line computer monitoring, offers an indirect method of measurement. Laboratory results from baker's yeast production in a 14-liter fermentor (with a PDP-11/10 computer for on-line analyses) show this indirect measurement technique to be a viable alternative. From the oxygen uptake and carbon dioxide production data, gas flow rate, and ammonia addition rate, the cell density during the fermentation has been estimated and found to compare well with actual fermentation data.     

BioMEMS device with integrated microdialysis probe and biosensor array

The fabrication of a microdevice for continuous sampling and on-line monitoring of glucose is described. The device comprised a microdialysis sampling system integrated on the flow through channel of a microfabricated enzyme sensor. The sensor was produced by thin film technology and was assembled to a printed circuit board (PCB) that provided the means for both electrical and fluidic connections. A polyacrilonitrile fibre, with a cut-off of 50 kDa, was used in the fabrication of the sampling probe. The performance of the device was evaluated in-vitro. High sampling efficiency of the microdialysis probe was achieved by appropriate selection of the perfusion fluid flow rate. Response times varying from 1.5 to 3.0 min were determined for flow rates ranging between 1 and 0.2 micro l/min. The linear response range was up to 30 mM glucose and interference from other electroactive substances was almost negligible. The device showed excellent stability under continuous operation for at least 5 days and sensitivity variation less than 3% over a period of 15 days.     

Monitoring of recombinant protein production using bioluminescence in a semiautomated fermentation process

On-line optimization of fermentation processes can be greatly aided by the availability of information on the physiological state of the cell. The goal of our "BioLux" research project was to design a recombinant cell capable of intracellular monitoring of product synthesis and to use it as part of an automated fermentation system. A recombinant plasmid was constructed containing an inducible promoter that controls the gene coding for a model protein and the genes necessary for bioluminescence. The cells were cultured in microfermenters equipped with an on-line turbidity sensor and a specially designed on-line light sensor capable of continuous measurement of bioluminescence. Initial studies were done under simple culture conditions, and a linear correlation between luminescence and protein production was obtained. Such specially designed recombinant bioluminescent cells can potentially be applied for model-based inference of intracellular product formation, as well as for optimization and control of recombinant fermentation processes.     

On-line monitoring and control of acetone-butanol fermentation by membrane-sensor mass spectrometry

A mass spectrometry (MS) membrane sensor was developed and applied to on-line product measurement in acetone-butanol fermentation. The sensor facilitated the monitoring of acetone, butanol, ethanol, H₂ and CO₂, and single-compound calibration curves for both acetone and butanol showed a linear relationship between the product concentration and the MS response. However, when an actual fermentation was monitored, the product concentration calculated from the MS response was smaller than the concentration determined by gas chromatography, and the relationship between the response and the product concentration was nonlinear. It was found that large amounts of gases (H₂, CO₂) entering the MS analyzation chamber were causing a ‘space charge effect’, which resulted in an MS response ceiling. The problem could be resolved by reducing the surface area of the sensor membrane. Under some fermentation conditions, a by-product, n-butyl butyrate, was produced, and this interfered with the measurement of butanol due to a peak overlapping effect. However, it was found that this could be compensated for by using an empirical equation. Application of the MS membrane sensor in a fed batch culture of acetone-butanol fermentation resulted in successful control of the butanol concentration.     

On-line near infrared monitoring of glycerol-boosted anaerobic digestion processes: evaluation of process analytical technologies

A study of NIR as a tool for process monitoring of thermophilic anaerobic digestion boosted by glycerol has been carried out, aiming at developing simple and robust Process Analytical Technology modalities for on-line surveillance in full scale biogas plants. Three 5 L laboratory fermenters equipped with on-line NIR sensor and special sampling stations were used as a basis for chemometric multivariate calibration. NIR characterisation using Transflexive Embedded Near Infra-Red Sensor (TENIRS) equipment integrated into an external recurrent loop on the fermentation reactors, allows for representative sampling, of the highly heterogeneous fermentation bio slurries. Glycerol is an important by-product from the increasing European bio-diesel production. Glycerol addition can boost biogas yields, if not exceeding a limiting 5-7 g L(-1) concentration inside the fermenter-further increase can cause strong imbalance in the anaerobic digestion process. A secondary objective was to evaluate the effect of addition of glycerol, in a spiking experiment which introduced increasing organic overloading as monitored by volatile fatty acids (VFA) levels. High correlation between on-line NIR determinations of glycerol and VFA contents has been documented. Chemometric regression models (PLS) between glycerol and NIR spectra needed no outlier removals and only one PLS-component was required. Test set validation resulted in excellent measures of prediction performance, precision: r(2) = 0.96 and accuracy = 1.04, slope of predicted versus reference fitting. Similar prediction statistics for acetic acid, iso-butanoic acid and total VFA proves that process NIR spectroscopy is able to quantify all pertinent levels of both volatile fatty acids and glycerol.     

Analysis of single-chain antibody production in Pichia pastoris using on-line methanol control in fed-batch and mixed-feed fermentations.

In the last few years the Pichia pastoris expression system has been gaining more and more interest for the expression of recombinant proteins. Many groups have employed fermentation technology in their investigations because the system is fairly easy to scale up and suitable for the production in the milligram to gram range. A large number of heterologous proteins from different sources has been expressed, but the fermentation process technology has been investigated to a lesser extent. A large number of fermentations are carried out in standard bioreactors that may be insufficiently equipped to meet the demands of high-cell-density fermentations of methylotrophic yeasts. In particular, the lack of on-line methanol analysis leads to fermentation protocols that may impair the optimal expression of the desired products. We have used a commercially available methanol sensor to investigate in detail the effects of supplementary glycerol feeding while maintaining a constant methanol concentration during the induction of a Mut(+) strain of Pichia pastoris. Specific glycerol feed rates in the range of 38-4.2 mg. g(-1). h(-1) (mg glycerol per gram fresh weight per hour) were investigated. Expression of the recombinant scFv antibody fragment was only observed at specific feed rates below 6 mg. g(-1). h(-1). At low specific feed rates, growth was even lower than with methanol as the sole carbon source and the harvest expression level of the scFv was only half of that found in the control fermentation. These results show that glycerol inhibits expression driven by the AOX1 promoter even at extremely limited availability and demonstrate the benefits of on-line methanol control in Pichia fermentation research.     

Dual excitation ratiometric fluorescent pH sensor for noninvasive bioprocess monitoring: development and application

The development and application of a fluorescent excitation-ratiometric, noninvasive pH sensor for continuous on-line fermentation monitoring is presented. The ratiometric approach is robust and insensitive to factors such as source intensity, photobleaching, or orientation of the patch, and since measurements can be made with external instrumentation and without direct contact with the patch, detection is completely noninvasive. The fluorescent dye 8-hydroxy-1,3,6-pyrene trisulfonic acid was immobilized onto Dowex strongly basic anion-exchange resin, which was subsequently entrapped into a proton-permeable hydrogel layer. The sensor layer was polymerized directly onto a white microfiltration membrane backing that provided an optical barrier to the fluorescence and scatter of the fermentation medium. The ratio of emission intensity at 515 nm excited at 468 nm to that excited at 408 nm correlated well with the pH of clear buffers, over the pH range of 6-9. The sensor responded rapidly (<9 min) and reversibly to changes in the solution pH with high precision. The sterilizable HPTS sensor was used for on-line pH monitoring of an E. coli fermentation. The output from the indwelling sensor patch was always in good agreement with the pH recorded off-line with an ISFET probe, with a maximum discrepancy of 0.05 pH units. The sensor is easily adaptable to closed-loop feedback control systems.     

In situ microscopy for on-line characterization of cell-populations in bioreactors, including cell-concentration measurements by depth from focus

A new technique is presented which allows the use of a front-end sensor head for in situ and on-line characterization of cell concentration and cell size during fermentation. An epifluorescence microscope is mounted in a port of a bioreactor viewing directly into the agitated broth. Still images from cells are generated using pulsed illumination. They are directly visualized on a monitor and used for automatic image analysis. The cell concentration and morphological information are determined by counting and evaluating the cell images with respect to their depth from focus characteristic. An in situ microscope was successfully tested during yeast fermentations and yielded results which correlated well with results from a hemocytometer. (c) 1995 John Wiley & Sons, Inc.     

Closed-loop control of fed-batch cultures of recombinant Escherichia coli using on-line HPLC

This article describes a fully automated system for the on-line monitoring and closed-loop control of a fed-batch fermentation of recombinant Escherichia coli, and presents two case studies of its used in limiting production of unwanted byproducts such as acetic in fed-batch fermentations. The system had two components. The first components, on-line monitoring, comprised an aseptic sampling device, a microcentrifuge, and HPLC System. These instruments removed a Sample from a fermentor, spun it at high speed to separate solid and liquid components, and then automatically injected the supernatant onto an HPLC column for analysis. The second component consisted of control algorithms programmed using the LabView visual programming environment in a control computer that was linked via a remote components were linked so that results from the on-line HPLC were captured and used by the control algorithm was designed to demonstrate coarse feedback control to confirm the operability of the controller. The second case study showed how the system could be used in a more sophisticated feedings strategy providing fine control and limiting acetate concentration to a low level throughout the fermentation. (c) 1994 John Wiley & Sons, Inc.     

Experimental studies of network parameters and operational variables on recurrent backpropagation neural network adaptive control of penicillin acylase fermentation by Arthrobacter viscosus

This work is to investigate the on-line control of the fermentation by Arthrobacter viscosus. This species of bacteria can secrete penicillin acylase which is a key enzyme in pharmaceutical industry. The growth of more cells during the fermentation will obtain more enzyme. Both the enzyme activity and the cell growth are rather sensitive to the change of pH. Once the pH during a fermentation is not properly controlled, the decay of cells' activity will irreversibly occur. Two peristaltic pumps for supplying acidic and basic solutions, respectively, were connected for the regulation of pH. With superior ability in identification and prediction of dynamic time series, recurrent backpropagation network (RBPN), instead of conventional controllers, was used as the adaptive controller model for the fermentation with dynamic characteristics. Based on a 1-3-1 BPN, a corresponding 4-4-1 RBPN was determined. The deviation of the pH measured at current time from the set point of 7.0, denoted as ( pH(t), was chosen as the input node of the network controller. The output node of this network controller was the predicted flow rate of the peristaltic pump for next control time interval. Such a model was operated by two phases. During the first phase, the network was set as the process model and trained by a fixed set of on-line acquired data. During the second phase, the network was stopped learning and switched to become a predictor, the predicted control action was hence obtained. The optimum sampling time was determined experimentally. To enhance the effective computation of this network, the number of training data was limited. A moving-window type of supplying training data to the network was applied for the on-line learning. The window size was also determined for each learning. With properly chosen network parameters as well as operation conditions, pH of the fermentation was thus well controlled by the RBPN controller.     

Neural network modeling for on-line estimation of nutrient dynamics in a sequentially-operated batch reactor.

In monitoring and controlling wastewater treatment processes, on-line information of nutrient dynamics is very important. However, these variables are determined with a significant time delay. Although the final effluent quality can be analyzed after this delay, it is often too late to make proper adjustments. In this paper, a neural network approach, a software sensor, was proposed to overcome this problem. Software sensor refers to a modeling approach inferring hard-to-measure process variables from other on-line measurable process variables. A bench-scale sequentially-operated batch reactor (SBR) used for advanced wastewater treatment (BOD plus nutrient removal) was employed to develop the neural network model. In order to improve the network performance, the structure of neural network was arranged in such a way of reflecting the change of operational conditions within a cycle. Real-time estimation of PO3-(4), NO-3, and NH+4 concentrations was successfully carried out with the on-line information of the SBR system only.     

An on-line sampling system for fermentation monitoring using membrane inlet mass spectrometry (MIMS): application to phenoxyacetic acid monitoring in penicillin fermentation

A sampling system for on-line monitoring of organic compounds of low volatility in complex fermentation media uses membrane inlet mass spectrometry (MIMS). A Syringe pump draws a continuous flow of microfiltered broth from the reactor and circulates it after acidification through a membrane inlet, in which a membrane is the only interface between the sample and the high vacuum of a mass spectrometer. All operations run automatically, i.e., sampling, acidification measurement, and calibration. The on-stream acidification enables MIMS monitoring of carboxylic acids, as they must be undissociated in order to pass the hydrophobic membrane. The performance of the monitoring system was tested by measurements of standard solutions of phenoxyacetic acid (POAA, the sie chain precursor of penicillin-V) as well as on POAA during 200 h penicillin-V fermentation. During the entire fermentation POAA was monitored n low millimolar concentrations with high accuracy and fast response to step changes in POAA concentration. Tandem mass spectrometry (MS/MS) allowed direct identification of peaks in the mass spectrum of the broth that were not accounted for by POAA. These peaks were identified as SO(2) and SCO. (c) 1994 John Wiley & Sons, Inc.