Evaluation of criteria for bioreactor comparison and operation standardization for mammalian cell culture

Development of bioprocesses with mammalian cell culture deals with different bioreactor types and scales. The bioreactors might be intended for generation of cell inoculum and production, research, process development, validation, or transfer purposes. During these activities, not only the difficulty of up and downscaling might lead to failure of consistency in cell growth, but also the use of different bioreactor geometries and operation conditions. In such cases, criteria for bioreactor design and process transfer should be carefully evaluated in order to select appropriate cultivation parameters. In this work, power input, mixing time, impeller tip speed, and Reynolds number have been compared systematically for the cultivation of the human cell line AGE1.HN within three partner laboratories using five different bioreactor systems. Proper operation ranges for the bioreactors were identified using the maximal cell‐specific growth rate (μ_max) as indicator. Common optimum values for process transfer criteria were found in these geometrically different bioreactors, in which deviations of μ_max between cultivation systems can be importantly reduced. The data obtained in this work are used for process standardization and comparability of results obtained in different bioreactor systems, i.e. to guarantee lab‐to‐lab consistency for systems biology approaches using mammalian cells.     

Production of Superoxide Dismutase from Streptococcus lactis Using a Bioreactor with a Microfiltration Module

The performance of a bioreactor with a microfiltration module for the production of an intracellular enzyme, superoxide dismutase (SOD), by Streptococcus lactis is described. The fermentation system involving the bioreactor enables the continuous removal of metabolites inhibitory for cell growth and the complete recycling of the cells to the bioreactor. In a fed-batch (FB) culture with filtration, in which the main metabolite, lactic acid, in the culture broth was maintained at a low concentration, S. lactis was cultivated to the high concentration of 15.5 g-dry cells/1. The SOD content of the cells remained at almost a constant level throughout the cultivation and the productivity of SOD as well as cells per unit time was 4.3-fold as high as that in the case of a conventional batch culture without filtration. Repeating the FB culture with filtration enhanced the productivities of SOD and cells further, as compared with those in the case of the FB culture with filtration.     

NaCS‐PDMDAAC immobilized cultivation of recombinant Dictyostelium discoideum for soluble human Fas ligand production

Dictyostelium discoideum is a promising eukaryotic host for the expression of heterologous proteins requiring post‐translational modifications. However, the dilute nature of D. discoideum cell culture limits applications for high value proteins production. D. discoideum cells, entrapped in sodium cellulose sulfate/poly‐dimethyl‐diallyl‐ammonium chloride (NaCS‐PDMDAAC) capsules were used for biosynthesis of the heterologous protein, soluble human Fas ligand (hFasL). Semi‐continuous cultivations with capsules recycling were carried out in shake flasks. Also, a scaled‐up cultivation of immobilized D. discoideum for hFasL production in a customized vitreous airlift bioreactor was conducted. The results show that NaCS‐PDMDAAC capsules have desirable biophysical properties including biocompatibility with the D. discoideum cells and good mechanical stability throughout the duration of cultivation. A maximum cell density of 2.02 × 10⁷ cells mL^?1 (equivalent to a maximum cell density of 2.22 × 10⁸ cells mL^?1 in capsules) and a hFasL concentration of 130.40 μg L^?1 (equivalent to a hFasL concentration of 1434.40 μg L^?1 in capsules) were obtained in shake flask cultivation with capsules recycling. Also, a maximum cell density of 1.72 × 10⁷cells mL^?1 (equivalent to a maximum cell density of 1.89 × 10⁸ cells mL^?1 in capsules) and a hFasL concentration of 106.10 μg L^?1 (equivalent to a hFasL concentration of 1167.10 μg L^?1 in capsules) were obtained after ～170 h cultivation in the airlift bioreactor (with a working volume of 200 mL in a 315 mL bioreactor). As the article presents a premier work in the application of NaCS‐PDMDAAC immobilized D. discoideum cells for the production of hFasL, more work is required to further optimize the system to generate higher cell densities and hFasL titers for large‐scale applications. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 31:424–430, 2015     

Bioprocess considerations for production of secondary metabolites by plant cell suspension cultures

Plant cell culture provides a viable alternative over whole plant cultivation for the production of secondary metabolites. In order to successfully cultivate the plant cells at large scale, several engineering parameters such as, cell aggregation, mixing, aeration, and shear sensitivity are taken into account for selection of a suitable bioreactor. The media ingredients, their concentrations and the environmental factors are optimized for maximal synthesis of a desired metabolite. Increased productivity in a bioreactor can be achieved by selection of a proper cultivation strategy (batch, fed-batch, two-stageetc.), feeding of metabolic precursors and extraction of intracellular metabolites. Proper understanding and rigorous analysis of these parameters would pave the way towards the successful commercialization of plant cell bioprocesses.     

Periodic harvesting of embryonic stem cells from a hollow‐fiber membrane based four‐compartment bioreactor

Different types of stem cells have been investigated for applications in drug screening and toxicity testing. In order to provide sufficient numbers of cells for such in vitro applications a scale‐up of stem cell culture is necessary. Bioreactors for dynamic three‐dimensional (3D) culture of growing cells offer the option for culturing large amounts of stem cells at high densities in a closed system. We describe a method for periodic harvesting of pluripotent stem cells (PSC) during expansion in a perfused 3D hollow‐fiber membrane bioreactor, using mouse embryonic stem cells (mESC) as a model cell line. A number of 100 × 10⁶ mESC were seeded in bioreactors in the presence of mouse embryonic fibroblasts (MEF) as feeder cells. Over a cultivation interval of nine days cells were harvested by trypsin perfusion and mechanical agitation every second to third culture day. A mean of 380 × 10⁶ mESC could be removed with every harvest. Subsequent to harvesting, cells continued growing in the bioreactor, as determined by increasing glucose consumption and lactate production. Immunocytochemical staining and mRNA expression analysis of markers for pluripotency and the three germ layers showed a similar expression of most markers in the harvested cells and in mESC control cultures. In conclusion, successful expansion and harvesting of viable mESC from bioreactor cultures with preservation of sterility was shown. The present study is the first one showing the feasibility of periodic harvesting of adherent cells from a continuously perfused four‐compartment bioreactor including further cultivation of remaining cells. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 32:141–151, 2016     

Fed-batch cultivation for the production of clavulanic acid by an immobilized Streptomyces clavuligerus mutant

In order to obtain high productivity of clavulanic acid, a newly-introduced carrier, polyurethane pellet (PUP) Z97-020 was used for the immobilization process. In a stirred-tank bioreactor, batch cultivation by Streptomyces clavuligerus KK immobilized on PUP Z97-020 gave about 3100 mg of clavulanic acid per litre, representing an increase of 200% in productivity compared with that by fed-batch cultivation of free cells (1500 mg/l). However, the clavulanic acid produced rapidly decomposed due to the pH change during batch cultivation. Fed-batch cultivation by immobilized S. clavuligerus KK gave an excellent level of clavulanic acid up to 3250 mg/l, a productivity increase of 220% compared with that by fed-batch cultivation of free cells. These results suggest that immobilization with PUP Z97-020 is a more effective process for the production of clavulanic acid and that the maintenance of pH by fed-batch cultivation with glycerol as a limiting substrate prevents the clavulanic acid from decomposing during the fermentation.     

In sito galanthamine extraction during the cultivation of Leucojum aestivum L. shoot culture in two‐phase bubble column cultivation system

Two‐phase bioreactor cultivation system was developed and applied for in sito recovery of extracellular galanthamine during the cultivation of Leucojum aestivum L. shoot culture in a modified column bioreactor system. The inclusion of an external circulation column with adsorbent resin Amberlite XAD‐4 as a second phase, on the 21st day of the beginning of cultivation resulted in 1.25 folds increase in biomass accumulation and maximal amounts of accumulated galanthamine of 6 mg/L (3.1 mg/L intracellular and 2.9 mg/L extracellular). It was demonstrated that the inclusion of a second phase at the cultivation of the L. aestivum shoot culture in a bubble column bioreactor with internal sections redirected the alkaloid metabolism to galanthamine synthesis and inhibits the synthesis of hemanthamine and lycorine type alkaloids. Our research demonstrated that the application of the two‐phase cultivation systems could be an important tool to increase the yields of valuable secondary metabolites in plant tissue culture‐based bioprocess.     

Bioreactor for solid-state cultivation of <Emphasis Type="Italic">Phlebiopsis gigantea</Emphasis>

Phlebiopsis gigantea fungus used in biological control of root rot is currently cultivated commercially in disposable, sterilizable plastic bags. A novel packed bed bioreactor was designed for cultivating P. gigantea and compared to the plastic bag method and to a tray bioreactor. The spore viability of 5.4 × 10⁶ c.f.u./g obtained with the packed bed bioreactor was of the same order of magnitude as the viabilities obtained with the other cultivation methods. Furthermore, the packed bed bioreactor was less time and space consuming and easier to operate than the tray bioreactor.     

Economic Mass Cultivation of Paramecium tetraurelia on a 200-Liter Scale1

ABSTRACT. A new and inexpensive medium is described for axenic mass cultivation of Paramecium tetraurelia stock 51s and the double mutant pawn A/pawn B. Skim milk powder is the major carbon and nitrogen source in this medium. Growth characteristics (proliferation rate, final cell density, and cell size) are similar to those observed with other axenic culture media. Cultures were run in one-liter erlenmeyer flasks, a 20-liter, and a 250-liter airlift bioreactor. The yield of a large bioreactor is 750 g (wet wt.) Paramecium or 5 × 10⁹ cells. This easy, economical culture technique will greatly facilitate the use of Paramecium as a model organism for extensive biochemical studies.     

Process optimization of the integrated synthesis and secretion of ectoine and hydroxyectoine under hyper/hypo‐osmotic stress

The synthesis and secretion of the industrial relevant compatible solutes ectoine and hydroxyectoine using the halophile bacterium Chromohalobacter salexigens were studied and optimized. For this purpose, a cascade of two continuously operated bioreactors was used. In the first bioreactor, cells were grown under constant hyperosmotic conditions and thermal stress driving the cells to accumulate large amounts of ectoines. To enhance the overall productivity, high cell densities up to 61 g L^?1 were achieved using a cross‐flow ultrafiltration connected to the first bioreactor. In the coupled second bioreactor the concentrated cell broth was subjected to an osmotic and thermal down‐shock by addition of fresh distilled water. Under these conditions, the cells are forced to secrete the accumulated intracellular ectoines into the medium to avoid bursting. The cultivation conditions in the first bioreactor were optimized with respect to growth temperature and medium salinity to reach the highest synthesis (productivity); the second bioreactor was optimized using a multi‐objective approach to attain maximal ectoine secretion with simultaneous minimization of cell death and product dilution caused by the osmotic and thermal down‐shock. Depending on the cultivation conditions, intracellular ectoine and hydroxyectoine contents up to 540 and 400 mg per g cell dry weight, respectively, were attained. With a maximum specific growth rate of 0.3 h^?1 in defined medium, productivities of approximately 2.1 g L^?1 h^?1 secreted ectoines in continuous operation were reached. Biotechnol. Bioeng. 2010;107: 124–133. © 2010 Wiley Periodicals, Inc.     

Investigation of the bacitracin biosynthesis in an airlift bioreactor

Results of pilot plant studies using an external-loop airlift bioreactor (170 l fermentation volume, liquid height-to-riser diameter: 27, loop-to-tower cross-section-area: 0.1225) have proven the relative merits of such a system in the bacitracin biosynthesis produced by the Bacillus licheniformis submerged aerobic cultivation. The results were compared to those obtained in a pilot-scale stirred-tank bioreactor with the same values of k_La. Excepting the aeration rate of 0.2 vvm, the fermentation process performed at 0.5 vvm and 1/0 vvm, respectively, unfolded similarly in the two fermentation devices with respect to the cell mass production, substrate utilization and bacitracin production during the fermentation process. In the riser section of the airlift bioreactor, the dissolved oxygen levels were higher, while in the downcomer section they were lower than those realized in the stirred tank bioreactor. Power requirements of the airlift fermenter were by 17–64% lower than those for a mechanically agitated system, depending on the aeration rates, which led to an important energy saving. Moreover, the lack of mechanical devices in the airlift system provides safety and a more gentle environment for the cultivation of microorganisms.     

Continuous suspended cell culture of Mentha piperita in cell-recycled air-lift bioreactor

Summary A cell-recycled air-lift bioreactor was studied for its performance in cultivation of Mentha piperita cells producing essential oils. The reactor system sustained a stable operation over 30 days with the aid of a cell settler. The maximum cell concentration reached 50% packed cell volume and it occurred at the dilution rate of 0.27 day^-1. Volumetric productivity of essential oils in this system was substantially higher than that obtainable from batch culture.     

Antioxidants enhanced production of destruxin E from cultivation of Metarhizium anisopliae

The effect of antioxidants on the production of an important cyclohexadepsipeptide congener destruxin E (dtx E) was investigated using the entomopathogenic fungus Metarhizium anisopliae F061. In shaker flask cultivations, 0.015% of menadione-enhanced dtx E production of 220.4 mg/l compared to the control cultivation 90.2 mg/l, which was illustrated by stimulation of dtx E biosynthesis through two electron reduction DT-diaphorase processes in cultivation of M. anisopliae. In 5-l stirred-tank bioreactor cultivation with menadione addition and of control pH 4.0, a yield of 454.6 mg/l of dtx E was obtained after 7 days, and was nearly 30 and 15-fold higher than that from no pH control, and controlled pH 2.0 cultivations, respectively. Further cultivation in a 20-l airlift bioreactor, at pH 4.0, dtx E obtained on the 9th day was 406.0 mg/l, which was much higher than the standard cultivation of no pH control yield 203.3 mg/l on the 11th day. Thus, the present study provides useful information for enhancing dtx E production in cultivation.     

Effect of temperature on the physiology and cytology of the methylotrophic yeastCandida boidinii growing in methanol-limited chemostat

All deviations from optimum cultivation temperature affect strongly the physiology and morphology of cells ofCandida boidinii strain 2 during growth in methanol-limited chemostat. The optimum cultivation temperature was 28–30 °C at which maximum cell concentration and maximum cell yield (Y _S 0.4 g/g) were achieved. At suboptimal growth temperatures the cells were rich in cell protein, RNA, alcohol oxidase (AO) and in peroxisomes. Formation of cubic peroxisomes and a 20 % decrease of budding cells in the population was observed. At supraoptimal growth temperatures (>30 °C) a sharp decrease in AO activity was accompanied by degradation of peroxisomes in the cells. The culture forms pseudomycelium: at 34 °C the cells stop growing and they are washed out of the bioreactor.     

Bioprocess development for the cultivation of human T-lymphocytes in a clinical scale

Adoptive transfer of large numbers of donor-derived T-lymphocytesmay offer a promising treatment of a variety of viral and malignant diseases. The key step in this approach is the ex vivo generation of sufficient quantities of these cells in a short time.We have investigated the influence of several important cultivation parameters on the proliferation of human T-lymphocytes to develop a large-scale fermentation process usingdifferent types of stirred bioreactors. Such systems offer manypotential advantages over the static culture systems commonlyused today.Peripheral blood mononuclear cells of healthy but CMV positive donors were stimulated with monoclonal antibodies (anti-CD3 and anti-CD28) and Interleukin-2. The influence of osmolality, Interleukin-2 concentration, pH, oxygen tension, feeding strategyand temperature on T-cell proliferation was investigated and theoptimised conditions were transferred to a novel stirred suspension bioreactor with an especially designed magnetic stirrbar to minimize the shear force (working volume 550 ml) and a standard stirred vessel (working volume 1000 ml).Preferable conditions for the cultivation of primary T-lymphocytes were an osmolality of 276–330 mOsmol kg^-1,an Interleukin-2 concentration of 100 U ml^-1, a pH rangeof 7.0 to 7.3, an oxygen tension of 5–50% and a temperature of 38.5 °C. After 238 h of cultivation 2.8 × 10⁹ cells in the stirred vesseland 1.5 × 10⁹ cells in the suspension bioreactor were obtained with a percentage of T-cells >94%. The specificity of the cells wasmaintained during cultivation as proven by IFN- secretionafter exposure to a hCMV protein.     

Fluorescence-based real time monitoring and diagnostics of recombinant Pichia pastoris cultivations in a bioreactor

This study describes the application of the multivariate curve resolution (MCR) analysis technique for real-time analysis of culture fluorescence during recombinant Pichia pastoris cultivation in a bioreactor. Fluorescence spectra were acquired with an on-line dual excitation wavelength fluorometer and then used to develop a real time MCR-based bioprocess monitoring and diagnostics tool. Initial bioreactor experiments using two similar recombinant antibody secreting P. pastoris cell lines showed significant differences in protein production. To distinguish between the contributions of operating conditions and the specific cell line's genetic composition to the observed differences in protein production, the bioreactor experiments were repeated and accompanied by real time MCR analysis. The tests demonstrated high sensitivity of MCR-derived “pure concentration” profiles to growth as well as to initial conditions, thus enabling real-time cultivation process trend diagnostics and fault detection. © 2018 Her Majesty the Queen in Right of Canada © 2018 American Institute of Chemical Engineers Biotechnol. Prog., 35: e2761, 2019.     

Excess turbulence as a cause of turbohypobiosis in cultivation of microorganisms

The present review describes the influence of different types of mixing systems under excess turbulence conditions on microorganisms. Turbohypobiosis phenomena were described by applying a method for measurement of the kinetic energy of flow fluctuations based on the piezoeffect. It can be assumed that the shear stress effect (the state of turbohypobiosis) plays a role mainly when alternative mechanisms in cells cannot ensure a normal physiological state under stress conditions. Practically any system (inner construction of a bioreactor, culture and cultivation conditions, including mixing) requires its own optimisation to achieve the final goal, namely, the maximum product and/or biomass yields from substrate (Y _P/S or/and Y _X/S ), respectively. Data on the biotechnological performance of cultivation as well as power input, kinetic energy (e) of flow fluctuations, air consumption rate, rotational speed, tip speed, etc. do not correlate directly if the mixing systems (impellers-baffles) are dissimilar. Even the widely used specific power consumption cannot be relied upon for scaling up the cultivation performance using dissimilar mixing systems. A biochemical explanation for substrate and product transport via cell walls, carbon pathways, energy generation and utilisation, etc. furnishes insight into cellular interactions with turbulence of different origin for different types of microorganisms (single cells, mycelia forming cells, etc.).     

High density cultivation of Dictyostelium discoideum in a rotating polyurethane foam-bed bioreactor

The production of recombinant glycoproteins in Dictyostelium discoideum by conventional cell culture methods was limited by low cell density as well as low growth rate. In order to achieve high cell density cultivation, polyurethane foam (PUF) with high porosity was introduced as new matrix for the immobilization of D. discoideum. The results showed that about 88–93% cells of D. discoideum were adsorbed onto the PUF particles after 100 min equilibrium between adsorbed and free cells, and the highest immobilization rate was achieved by adding the same quantity of PUF matrix with the thin cylinder style. Furthermore, polyurethane foam was used as the immobilization matrix in a rotating PUF-bed bioreactor system. With batch cultures in the rotating bed bioreactor, the concentration of immobilized cells in the PUF carrier increased to 4.2 × 10⁷ cells ml⁻¹ after 167 h cultivation, which was about fourfold higher than the maximal cell density in the conventional free-cell culture. Further studies showed that the cells of D. discoideum were not just simply adsorbed on the surfaces, but actively attached to the surfaces through their network of pseudopodia or filopodia. The present work is very promising to improve the productivity of recombinant proteins in D. discoideum with high cell density in this novel rotating bed bioreactor.     

Overproducton of mannitol dehydrogenase in Rhodobacter sphaeroides

Mannitol dehydrogenase (MDH) from Rhodobacter sphaeroides Si4 was overproduced by constructing a strain that overexpresses the MDH gene and by producing high cell concentrations via fed-batch cultivation in a bioreactor. With the gene of mannitol dehydrogenase (mtlK) cloned into the expression vector pKK223-3 expression of MDH in Escherichia coli was obtained, but the specific enzyme activity was lower than in R. sphaeroides Si4. In order to overexpress mtlK in R. sphaeroides, plasmid pAK82 was constructed by cloning a DNA fragment carrying mtlK into the broad-host-range expression vector pRK415. When pAK82 was introduced into R. sphaeroides Si4 the specific mannitol dehydrogenase activity in the strain obtained was 0.48 unit (U)mg^–1, 3.4-fold higher thain in the wild type. In this way the enzyme yield from cultivation in a bioreactor could be improved from 110 Ul^–1 to 350 Ul^–1. A further increase in productivity was obtained by fed-batch cultivation of R. sphaeroides Si4 [pAK82]. Using this cultivation method can optical density of 27.6 was reached in the bioreactor, corresponding to a dry mass of 16.6 g l^–1. Since MDH formation correlated with biomass production, the MDH yield could be raised to 918 Ul^–1, an 8.3-fold increase in comparison to batch cultivation of the wild-type strain.Dedicated to Prof. Fritz Wagner on the occasion of his 65th birthday.     

Effect of submerged culture conditions on exopolysaccharides production by Armillaria luteo-virens Sacc QH and kinetic modeling

This work aimed to develop the submerged cultivation conditions for improved exopolysaccharides (EPS) production by Armillaria luteo-virens Sacc. The effects of culture temperature, aeration rate, inoculum level, initial pH, and additives on EPS formation and mycelial growth are investigated. The aeration rate, initial pH, and inoculum level significantly affected EPS production under the submerged cultivation. The developed conditions were as follows: cultivation temperature 23 °C, initial pH 5.0, aeration rate 0.5 vvm, 0.5% Tween 80, inoculum level 5% (v/v), and shaking speed 120 r/min. Under the developed conditions, the highest EPS production was 13.01 g/L at 5 days culture time. EPS production was examined in a 5 L bioreactor, and an unstructured kinetic model for EPS formation was well developed. The verified investigations in the large-scale cultivation system showed that the developed models are able to predict the submerged cultivation process of EPS formation. Current results revealed that the submerged cultivation conditions can be utilized to control EPS production, and the unstructured models developed are suitable for explaining EPS production by A. luteo-virens Sacc QH in a large-scale cultivation bioreactor.