Maximum production in a bakers' yeast fed-batch culture by a tubing method

A feedback control system of the glucose feed rate in a bakers' yeast fed-batch culture was developed by keeping the ethanol concentration constant. A PID controller and on–off controller were applied and discussed with the aid of the porous Teflon tubing method. Experimental results showed the effectiveness of the control system for avoiding the glucose effect and glucose starvation. It was shown that the feedback control system developed hare could achieve a maximum specific growth rate of 0.3 h^?1 or a maximum cell yield of 0.5 g cell/g glucose in the fedhyphen;batch culture.     

Application of porous teflon tubing method to automatic fed-batch culture of microorganisms. I. Mass transfer through porous teflon tubing

For the purpose of a rational design for an automatic feedback control system incorporating a porous Teflon tubing sensor in semibatch culture, steady-state mass-transfer characteristics of tubing sensors have been investigated theoretically and experimentally, and also dynamic responses have been studied experimentally. A distributed mathematical model for steady-state diffusion has been solved numerically and its solution has been shown as useful for the sensor design. The overall mass-transfer resistance of radial diffusion has been shown to be the sum of external liquid-film mass-transfer resistance and membrane diffusion resistance. The steady-state experiments using ethanol dissolved in water revealed that its transfer into the tubing was controlled by the molecular diffusion within the tubing-wall membrane. Oxygen transfer from external water into the tubing was shown experimentally to be controlled by the liquid-film resistance outside the tubing. In general, the radial mass transfer of a substance having a small Henry's constant is controlled by the liquid-film resistance. The response of the tubing sensor-detector-recorder system for the stepwise addition of ethanol into the external water could not be represented by a simple combined system of the first-order delay with lag time. The responses depend on the characteristics of the tubing as well as flow rate of the carrier gas, etc., but they were quite excellent in all cases (e.g., 90% in 20 s).     

Growth kinetics ofSaccharomyces cerevisiae in batch and fedbatch cultivation using sugarcane molasses and glucose syrup from cassava starch

Growth kinetics ofSaccharomyces cerevisiae in glucose syrup from cassava starch and sugarcane molasses were studied using batch and fed-batch cultivation. The optimum temperature and pH required for growth were 30°C and pH 5.5, respectively. In batch culture the productivity and overall cell yield were 0.31 g L^–1 h^–1 and 0.23 g cells g^–1 sugar, respectively, on glucose syrup and 0.22 g L^–1 h^–1 and 0.18 g cells g^–1 sugar, respectively, on molasses. In fed-batch cultivation, a productivity of 3.12 g L^–1 h^–1 and an overall cell yield of 0.52 g cells g^–1 sugar in glucose syrup cultivation and a productivity of 2.33 g L^–1 h^–1 and an overall cell yield of 0.46 g cells g^–1 sugar were achieved in molasses cultivation by controlling the reducing sugar concentration at its optimum level obtained from the fermentation model. By using an on-line ethanol sensor combined with a porous Teflon^® tubing method in automating the feeding of substrate in the fed-batch culture, a productivity of 2.15 g L^–1 h^–1 with a yield of 0.47 g cells g^–1 sugar was achieved using glucose syrup as substrate when ethanol concentration was kept at a constant level by automatic control.     

Use of an ethanol sensor for feedback control of growth and expression of TBV25H in Saccharomyces cerevisiae

A process for production of a malaria transmission blocking vaccine candidate under the control of the ADH2 promoter in Saccharomyces cerevisiae was developed. Monitoring and controlling the ethanol concentration during the process is essential for successful expression of the recombinant protein. A simple sensor accomplishing this task has been developed, the principle of its operation is the following: air-flow through silicone tubing submerged in the media picks up ethanol, which is detected by an alcohol sensor that relays a signal to a controller regulating the amount of ethanol added to the culture. The sensor was used successfully in high cell density cultures of various scales.     

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.     

On-line control of glucose concentration using an automatic glucose analyzer

The fundamental characteristics of an automatic glucose analyzer which consists of sampling, sensor, and operation units were examined. The glucose sensor is a dual cathode type which has an immobilized glucose oxidase membrane coupled with an oxygen sensor. Using this glucose sensor combined with an automatic sampling device, on-off control of the glucose concentration in fed-batch cultures of Saccharomyces cerevisiae was carried out. When the glucose concentration to be controlled was set at 0.3 and 10 g/l, the concentration was well maintained within the range of 0.08−0.54 g/l in the former, and within 9.2–11.1 g/l in the latter. In the former experiment, 1.67 g/l of ethanol was produced at the end of cultivation (OD₅₇₀=34). On the other hand, 12.9 g/l of ethanol was accumulated at the end of cultivation (OD₅₇₀=43) in the latter experiment. Fed-batch cultures of Micrococcus ruteus were also carried out. The glucose concentration was set at 2.5 g/l. The microorganism grew up to OD₆₁₀=264 and the glucose concentration was maintained within 2.0 and 3.1 g/l.     

Control of carbon source supply and dissolved oxygen by use of carbon dioxide concentration of exhaust gas in fed-batch culture

Accurate and automatic control strategies for a feedback-control system of volatile carbon source feeding and dissolved oxygen (DO) level were investigated. To maintain the optimal ethanol concentration for microbial growth, carbon dioxide concentration in exhaust gas was used as a stepwise control parameter of ethanol feeding. A proportional-differential (PD) control program was used to correct the errors. The coefficient of stepwise control was calculated stoichiometrically, and parameters of PD were experimentally preset and were not changed during cultivation. DO was also controlled by the PD control and the stepwise program based on carbon dioxide concentration of the exhaust gas. Agitation speed and partial pressure of oxygen of the inlet gas were changed stepwise in accordance with the oxygen consumption rate. The stepwise coefficients were estimated from stoichiometry and material balance of molecular oxygen. The PD control program was only used for the agitation speed control to correct the fluctuations of DO level. The parameters did not need to be changed during cultivation. By use of these sophisticated control programs for fed-batch culture of Candida brassicae, ethanol concentration and DO level were accurately controlled at 3.4–3.7 g/l and 2.2–2.8 ppm, respectively, while cell mass concentration reached about 80 g/l. No manual operation was needed.     

Cultivation of syntrophic anaerobic bacteria in membrane-separated culture devices

A dialysis culture device was used for growth of syntrophic fatty acid-oxidizing and ethanol-oxidizing anaerobic bacteria. A pure culture of the fatty acid oxidizer Clostridium bryantii was grown inside dialysis tubing which was surrounded by a pure culture of Desulfovibrio vulgaris. The same apparatus was used for the syntrophic cultivation of Pelobacter acetylenicus and Acetobacterium woodii with ethanol as substrate. In both cases, substrate degradation and product formation were about half as fast as with the homogeneously mixed control cultures. In the compartment of the hydrogen producer, the concentration of free hydrogen during syntrophic ethanol degradation was about 10 times as high as in that of the hydrogen utilizer, whereas the homogeneously mixed culture exhibited an intermediate hydrogen partial pressure.     

Growth of Nitrosomonas europaea in batch and continuous culture

Summary A clear medium has been used to grow pur cultures of Nitrosomonas europaea in flasks and in a continuous culture apparatus.Of several metallic ions examined in flask cultures of Nitrosomonas, Fe at 2 ppm and Co, Mn and Zn at 1 ppm were not toxic, Ni and Cr at concentrations greater than 0.25 ppm inhibited growth and Cu stopped growth completely at 0.5 ppm and inhibited at 0.1 ppm. Stainless steel of the specification EN58 B did not affect growth.In the continuous culture vessel, Nitrosomonas showed a growth response to Fe only when the population exceeded about 500×10⁶ organisms/ml. The minimum doubling time was about 8 hours in flasks and 11 hours in the culture vessel. With effective aeration and automatic P_H control, cultures of Nitrosomonas were grown successfully in continuous culture and gave a yield of 2.14 g dry weight of bacteria from 30 litres of culture in 5 days.     

Control of an ethanol fermentation carried out with alginate entrapped Saccharomyces cerevisiae

Process control of different reactor models for continuous production of ethanol from sucrose with immobilized yeast has been studied. An enzyme thermistor with immobilized invertase recorded the concentration of sucrose continuously. Ethanol was recorded by a membrane gas sensor with a SnO(2) semiconductor used as detector. A process computer controlled the substrate feed to keep substrate as well as ethanol concentration at preset values by using algorithms of varying complexity. It was thereby demonstrated that PID regulators as well as more advanced algorithms (Otto-Smith regulator, state feedback from a Kalman filter, and cascade control) are useful alternatives to maintain a constant concentration in the fermentor effluents. The time required for the system to return to predetermined conditions after various kinds of disturbances has been especially studied. It was shown that the more advanced regulator used the shorter time.     

Kinetics of yeast growth and enzyme syntheses in a phosphate-limited continuous culture

Summary The effect of a deficiency of inorganic phosphate on the growth rate and on the invertase and phosphatase activities inSaccharomyces carlsbergensis was studied in a chemostat culture using a synthetic medium in which ethanol was the sole carbon source.The kinetic relationship between the growth rate and both the rates of phosphate uptake and the ethanol consumption agreed well with the threshold model but not the multicative model. The invertase activity of the yeast increased as the dilution rate decreased. As the phosphate concentration in the feed was reduced, the enzyme synthesis increased remarkably. Acid phosphatase activity was repressed completely above a critical molecular ratio, 0.015, of monopotassium phosphate to ethanol in the feed medium. As the phosphate concentration in the feed decreased, the maximum specific enzyme activity increased and the corresponding optimum dilution rate decreased. These experimental changes in enzyme synthesis were expressed mathematically using the modified operon models for enzyme regulation in terms of two fractions of limited inorganic phosphate; one which affects growth and the other which is incorporated in excess by the cells.Nomenclature A ethanol concentration in the culture (mM) - a, b, c, d exponents in the operon model - D dilution rate (h^–1) - E enzyme concentration in the culture (enzyme unit l^–1) - K_a, K_b, K_c, K_d, k equilibrium constants used in the operon model, see Toda (1976b) - o operator gene - P inorganic phosphate concentration in the culture (mM) - Pi limited inorganic phosphate concentration in the cells (mmole inorganic phosphate/g dry weight of cell) - Q specific enzyme activity, no units: (E/X)/(E/X)_max - Q_c, Q_d as defined in Eq. 12 - R repressor - r regulator gene - X cell concentration in the culture (dry cell weight l^–1) Greek Letters molecular ratio of inorganic phosphate to ethanol in the feed medium (mole/mole) - specific growth rate (h^–1) - A specific uptake rate of ethanol (mmole/g cell·h) - P specific uptake rate of inorganic phosphate (mmole/g cell·h) Suffix crit critical value - f feed - max maximum - min minimum - t total - 1, 2 number of species Superfix eff effective for cell growth - exc excess - str structural     

Growth characteristics of Candida utilis in a multistage culture system

The effect of increasing ethanol concentration in the feed on the growth and physiological activity of the yeast Candida utilis was studied. At steady-state of continuous culture with constant values of dilution rate, temperature, and pH in all fermenters in series biomass, ethanol and volatile acid concentrations, biomass yield and productivity and respiration activity were measured. In the three-stage system the maximum biomass concentration in the effluent and maximum productivity was achieved between 20 and 25 g ethanol/l in the feed. At higher concentrations, ethanol negatively affects the coupling of oxidative phosphorylation and respiratory control of cells resulting in a decrease in biomass yield and intracellular protein content. It was shown that the presence of acetate in the medium inhibits the respiration activity of yeasts growing on ethanol.     

Fuzzy control of ethanol concentration its application to maximum glutathione production in yeast fed-batch culture

A fuzzy logic controller (FLC) for the control of ethanol concentration was developed and utilized to realize the maximum production of glutathione (GSH) in yeast fedbatch culture. A conventional fuzzy controller, which uses the control error and its rate of change in the premise part of the linguistic rules, worked well when the initial error of ethanol concentration was small. However, when the initial error was large, controller overreaction resulted in an overshoot.An improved fuzzy controller was obtained to avoid controller overreaction by diagnostic determination of "glucose emergency states" (i.e., glucose accumulation or deficiency), and then appropriate emergency control action was obtained by the use of weight coefficients and modification of linguistic rules to decrease the overreaction of the controller when the fermentation was in the emergency state. The improved fuzzy controller was able to control a constant ethanol concentration under conditions of large initial error.The improved fuzzy control system was used in the GSH production phase of the optimal operation to indirectly control the specific growth rate mu to its critical value mu(c). In the GSH production phase of the fed-batch culture, the optimal solution was to control mu to mu(c) in order to maintain a maximum specific GSH production rate. The value of mu(c) also coincided with the critical specific growth rate at which no ethanol formation occurs. Therefore, the control of mu to mu(c) could be done indirectly by maintaining a constant ethanol concentration, that is, zero net ethanol formation, through proper manipulation of the glucose feed rate. Maximum production of GSH was realized using the developed FLC; maximum production was a consequence of the substrate feeding strategy and cysteine addition, and the FLC was a simple way to realize the strategy. (c) 1993 John Wiley & Sons, Inc.     

Performance and stability of ethanologenic Escherichia coli strain FBR5 during continuous culture on xylose and glucose

Escherichia coli FBR5 containing recombinant genes for ethanol production on plasmids that are also required for anaerobic growth was cultivated continuously on 50 g/l xylose or glucose in the absence of antibiotics and without the use of special measures to limit the entry of oxygen into the fermenter. Under chemostat conditions, stable ethanol yields of ca. 80–85% of the theoretical were obtained on both sugars over 26 days at dilution rates of 0.045/h (xylose) and 0.075/h (glucose), with average plasmid retention rates of 96% (xylose) and 97% (glucose). In a continuous fluidized bed fermenter, with the cells immobilized on porous glass beads, the extent of plasmid retention by the free cells fell rapidly, while that of the immobilized cells remained constant. This was shown to be due to diffusion of oxygen through the tubing used to recirculate the medium and free cells. A change to oxygen-impermeable tubing led to a stable high rate of plasmid retention (more than 96% of both the free and immobilized cells) with ethanol yields of ca. 80% on a 50 g/l xylose feed. The maximum permissible level of oxygen availability consistent with high plasmid retention by the strain appears to be of the order of 0.1 mmol per hour per gram dry biomass, based on measurements of the rate of oxygen penetration into the fermenters. Revertant colonies lacking the ethanologenic plasmid were easily detectable by their morphology which correlated well with their lack of ampicillin resistance upon transfer plating.     

Automatic control for fed-batch culture of single cell protein

Candida utilis was cultivated in a 5-liter jar fermentor using ethanol as sole carbon source. Control of ethanol in the cultivation broth was performed by using an ethanol vapor monitoring instrument and an oxygen electrode coupled with two control circuits. By setting upper and lower bounds according to the predetermined conditions, a signal from a gas monitoring sensor switched the lower or higher bound relay governing the actuating or switch-off of the motor; this maintained a proper concentration of ethanol in the cultivation of ethanol in the system. The growth of cells was found to be satisfactory. Cell concentration reached 64 g/liter during a 20-hr cultivation. As the results of comparative experiments, the control mode using the gas monitoring instrument was found to be superior to that using dissolved oxygen as a controlling signal, especially at high cell concentration.     

Experience in using an ethanol sensor to control molasses feed-rates in baker's yeast production

An ethanol sensor has been tested for feed-rate control of baker's yeast prouction. The yeast was grown on molasses in an 8 dm³ fed-batch reactor up to a cell concentration of 60–70 kg/m³. Studies were made on three levels: reliability of the sensor system, characterisation of the control problem, and evaluation of ethanol-controlled cultivations in terms of yield and production rate. Arguments are given for the conceptual advantages of ethanol control compared to other methods of substrate control. It is also shown that ethanol control allows for a simple regulator structure. In fact, a PID regulator, with constant parameters, was used around an exponential dosage scheme. Tuning of the regulator parameters was performed by using simulation on a simplified model of the process. Several cultivations have been carried out. Results from four comparable cultivations are given in detail, and the experience from many others is summarized.     

Simulation and optimization of fed-batch culture for ethanol production from molasses

Two simulation methods for ethanol production from molasses by a flocculating yeast, Saccharomyces cerevisiae AM12, were investigated and molasses feeding was optimized. The first method was based on a deterministic model with fixed kinetic parameters and the second was based on regression analysis. The amount of ethanol produced in a fed-batch culture with multiple additions of molasses was simulated by both of these two methods. Simulated results of a fed-batch culture were compared with those of a simple batch culture by a model of regression analysis. The intermittent addition of molasses gave better production than a single addition at the beginning; more frequent addition may further improve production. The experimental results suggested the same. The effect of the amount of the added molasses on ethanol production was investigated by simulation. Repeated batch culture with and without intermittent addition of molasses in each batch was also done.List of Symbols C _e deviation of calculated results from experimental results - F m³ volume of feed medium added to the fermentor - P kg/m³ concentration of ethanol - P _M kg total amount of ethanol - S kg/m³ concentration of sugar - S ₀ kg/m³ concentration of sugar in the molasses feed medium - S _M kg total amount of sugar - V m³ culture volume - X kg/m³ concentration of cells - X _M kg total amount of cells - x _c calculated data - x _e experimental data - h^–1 specific rate of growth - kg-sugar/(kg-cell h) specific rate of sugar consumption - kg-ethanol/(kg-cell h) specific rate of ethanol production     

Effect of ractopamine and conjugated linoleic acid on performance of late finishing pigs

The dietary inclusion of feed additives to improve the carcass characteristics of the final product is of great importance for the pork production chain. The aim of our study was to evaluate the effects of the association of ractopamine (RAC) and conjugated linoleic acid (CLA) on the performance traits of finishing pigs during the last 26 days prior to slaughter. In total, 810 commercial hybrid barrows were used. Animals were distributed among treatments according to a randomised block design in a 3 × 3 factorial arrangement, with three RAC levels (0, 5 or 10 ppm) and three CLA levels (0, 0.3 or 0.6%). Pigs fed the diet with 5 ppm RAC had higher average daily feed intake (ADFI) (2.83 kg; P < 0.05) when compared with those fed 10 ppm RAC and the control diet (2.75 and 2.74 kg, respectively). Lower ADFI values (P < 0.01) were observed with the diets containing CLA compared with the control diet with no CLA (2.73 and 2.75 v. 2.85 kg/day, respectively). The average daily weight gain of pigs fed 5 and 10 ppm RAC was +148 and +173 g/dayhigher (P < 0.001), respectively, than those fed the control diet. Dietary RAC levels influenced (P < 0.001) feed conversion ratio (FCR), which was reduced as RAC levels increased, with the pigs fed 10, 5 and 0 ppm RAC presenting FCR values of 2.57, 2.71 and 3.05, respectively. FCR also improved (P < 0.05) with the inclusion of 0.6% CLA relative to the control diet (2.70 v. 2.84, respectively). There was a significant interaction between CLA × RAC levels (P < 0.01) for final BW, loin eye area (LEA) (P < 0.05) and backfat thickness (BT) (P < 0.05). The treatments containing 10 ppm RAC + 0.6% or 0.3% CLA increased LEA and reduced BT. In conclusion, the level of 10 ppm inclusion of RAC increased the overall performance parameters of pigs and therefore improved production efficiency. The combined use of RAC and CLA promoted a lower feed conversion ratio as well as better quantitative carcass traits, as demonstrated by the higher LEA and lower BT. The dietary inclusion of CLA at 0.3% improved feed efficiency, however, without affecting LEA or BT yields.     

Mass production of lipase by fed-batch culture of Pseudomonas fluorescens

Summary High concentration production of an extracellular enzyme, lipase, was achieved by a fed-batch culture of Pseudomonas fluorescens. During the cultivation, temperature, pH and dissolved oxygen concentration wwre maintained at 23°C, 6.5 and 2–5 ppm, respectively. Olive oil was used as a carbon source for microbial growth. To produce lipase effectively the specific feed rate of olive oil had to be maintained in a range of 0.04–0.06 (g oil) · (g dry cell)^-1 · h^-1. The CO₂ evolution rate was monitored to estimate the requirement of olive oil. The ratio of feed rate of olive oil to the CO₂ evolution rate was varied in the range of 20–60 g oil/mol CO₂. The higher value of the ratio accelerated microbial growth, but did not favour lipase production. Once the high cell concentration of 60 g/l had been achieved, the ratio was changed from 50 to 30 g oil/mol CO₂ to accelerate the lipase production. By this CO₂-dependent method a very high activity of lipase, 1980 units/ml, was obtained. Both the productivity and yield of lipase were prominently increased compared with a conventional batch culture.     

Optimization and control of perfusion cultures using a viable cell probe and cell specific perfusion rates

Consistent perfusion culture production requires reliable cell retention and control of feed rates. An on-line cell probe based on capacitance was used to assay viable biomass concentrations. A constant cell specific perfusion rate controlled medium feed rates with a bioreactor cell concentration of ∼5 × 10⁶ cells mL^-1. Perfusion feeding was automatically adjusted based on the cell concentration signal from the on-line biomass sensor. Cell specific perfusion rates were varied over a range of 0.05 to 0.4 nL cell^-1 day^-1. Pseudo-steady-state bioreactor indices (concentrations, cellular rates and yields) were correlated to cell specific perfusion rates investigated to maximize recombinant protein production from a Chinese hamster ovary cell line. The tissue-type plasminogen activator concentration was maximized (∼40 mg L^-1) at 0.2 nL cell^-1 day^-1. The volumetric protein productivity (∼60 mg L^-1 day^-1 was maximized above 0.3 nL cell^-1 day^-1. The use of cell specific perfusion rates provided a straightforward basis for controlling, modeling and optimizing perfusion cultures. This revised version was published online in July 2006 with corrections to the Cover Date.