On-line characterization of a hybridoma cell culture process

The on-line determination of the physiological state of a cell culture process requires reliable on-line measurements of various parameters and calculations of specific rates from these measurements. The cell concentration of a hybridoma culture was estimated on-line by measuring optical density (OD) with a laser turbidity probe. The oxygen uptake rate (OUR) was determined by monitoring dynamically dissolved oxygen concentration profiles and closing oxygen balances in the culture. The base addition for neutralizing lactate produced by cells was also monitored on-line via a balance. Using OD and OUR measurements, the specific growth and specific oxygen consumption rates were determined on-line. By combining predetermined stoichiometric relationships among oxygen and glucose consumption and lactate production, the specific glucose consumption and lactate production rates were also calculated on-line. Using these on-line measurements and calculations, the hybridoma culture process was characterized on-line by identifying the physiological states. They will also facilitate the implementation of nutrient feeding strategies for fed-batch and perfusion cultures. (c) 1994 John Wiley & Sons, Inc.     

On-line measurement and control of cell concentration of Saccharomyces cerevisiae using a laser turbidimeter

Summary On-line measurement and control of cell concentration of Saccharomyces cerevisiae using a laser turbidimeter was carried out. Effects on the turbidity measurement of operating parameters such as agitation speed, aeration rate, and the concentration of antifoam agent were investigated. Correlations between the on-line-measured turbidity and the off-line dry cell weight concentration were made at various operating conditions. Using the correlations the cell concentration was successfully estimated in a range of up to 8 g/L in batch cultures. The on-line monitoring and regulation of the cell concentration in a range of up to 35 g/L were also satisfactory in continuous and turbidostat cultures with cell recycle.     

Critical analysis of quantitative indicators of cell disruption applied to Saccharomyces cerevisiae processed with an industrial high pressure homogenizer

A comparison of quantification techniques was performed on suspensions of Saccharomyces cerevisiae which had been disrupted with a high pressure homogenizer. The quantification techniques included cell counting, monitoring protein release, UV absorbance, turbidity, sample mass loss analysis, variations in viscosity and measuring the particle size distribution of the homogenate. It was found that all quantification techniques resulted in similar relationships between the measured extent of disruption and number of passes through the homogenizer. The data from all techniques (except particle sizing) could be fitted to simple exponential decay models at various homogenization pressures. Turbidity, particle sizing and UV absorbance generally gave more conservative estimates of the extent of cell disruption compared to protein release and cell counting. Measuring both the turbidity and monitoring the release of cellular metabolites using UV absorbance gave simple, reliable and reproducible measures of disruption and were identified as being the most applicable to on-line disruption monitoring.     

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 of pullulanase production during continuous culture of Clostridium thermosulfurogenes

Summary An automated turbidimetric immunoassay for pullulanase from Clostridium thermosulfurogenes was developed for on-line bioprocess monitoring. Measurements are based on the turbidity caused by specific aggregation between pullulanase molecules present in the cultivation medium and antibodies against these enzymes. The time for one assay cycle is 3.0 min. Pullulanase concentrations between 10 units (U)/l and 1000 U/l could be measured. Standard deviations of less than 2% were found. The analysis system could be successfully employed for on-line product monitoring during a 240-h cultivation of C. thermosulfurogenes. An average correlation factor of 0.975 was obtained for the pullulanase data from on-line turbidimetric and the off-line reference assay, demonstrating the accuracy of this on-line method. Offprint requests to: Th. Scheper     

On-line measurement of cell mass and specific growth rate by a laser turbidity meter coupled with data smoothing using a one-pass method

Summary A data smoothing algorithm by a one-pass method, employing spline function was applied to a laser turbidity meter for on-line measurement of cell mass and specific growth rate in the culture using recombinant E.coli The outputs from the laser turbidity meter containing noise and errors were successfully filtered by the method, leading to more reliable estimation of cell mass and specific growth rate in real time.     

Algae and rotifer turbidostats: studies on stability of live feed cultures

A two stage turbidostat was developed according toBoraas & Bennet (1988), but with highly improvedturbidity sensors. The first stage was an algalturbidostat where algal density was regulated byturbidity measurements. Algal density was also heldconstant in the second stage (rotifer production)according to turbidity measurements. Additionally,the growth rates were monitored. The regulation system allowed an effective on-line process control.Initially, the production of rotifers in long-timestudies was variable. However, after furtherimprovements of the turbidity measurement, fluctuations in the rotifer turbidostat decreasedsignificantly.     

High-level secretion of functional green fluorescent protein from transgenic tobacco cell cultures: characterization and sensing

Green fluorescent protein (GFP) is useful for studying protein trafficking in plant cells. This utility could potentially be extended to develop an efficient secretory reporter system or to enable on-line monitoring of secretory recombinant protein production in plant cell cultures. Toward this end, the aim of the present study was to: (1) demonstrate and characterize high levels of secretion of fluorescent GFP from transgenic plant cell culture; and (2) examine the utility of GFP fluorescence for monitoring secreted recombinant protein production. In this study we expressed in tobacco cell cultures a secretory GFP construct made by splicing an Arabidopsis basic chitinase signal sequence to GFP. Typical extracellular GFP accumulation was 12 mg/L after 10 to 12 days of culture. The secreted GFP is functional and it accounts for up to 55% of the total GFP expressed. Findings from culture treatments with brefeldin A suggest that GFP is secreted by the cultured tobacco cells via the classical endoplasmic reticulum-Golgi pathway. Over the course of flask cultures, medium fluorescence increased with the secreted GFP concentrations that were determined using either Western blot or enzyme-linked immunoassay. Real-time monitoring of secreted GFP in plant cell cultures by on-line fluorescence detection was verified in bioreactor cultures in which the on-line culture fluorescence signals showed a linear dependency on the secreted GFP concentrations.     

On-line monitoring of cell concentration of Perilla frutescens in a bioreactor

This article demonstrates the successful in situ real-time monitoring of the cell concentration of Perilla frutescens in a bioreactor by using a laser turbidimeter. It was found that turbidity measurements at 780 nm with the laser sensor were hardly affected by the red color of the anthocyanin produced by P. frutescens cells, nor by the aeration rate or agitation speed within the ranges investigated. There was an excellent linear relationship, with a correlation coefficient (r(2)) higher than 0.99, between the sensor's response and the cell concentration. The whole growth stage of the cells, i.e., lag, logarithmic, and stationary phases, in bioreactor cultivations, could be satisfactorily estimated on-line by means of the in situ turbidimeter. However, during the declining phase of the cells, an apparent deviation was observed between the on-line estimations and off-line measurements of cell concentrations by dry cell weight, while the wet cell weight could be estimated by the same turbidimeter system. We found that this deviation was caused by a decrease in the cell density due to an increase of the individual cell volume and a decrease of the cell dry weight during the declining phase. (c) 1993 John Wiley & Sons, Inc.     

Optical waveguide lightmode spectroscopy as a new method to study adhesion of anchorage-dependent cells as an indicator of metabolic state

Optical Waveguide Lightmode Spectroscopy (OWLS) is based on measurements of the effective refractive index of a thin layer above the waveguide. Its potential as a whole-cell biosensor was demonstrated recently monitoring adhesion and spreading of Baby Hamster Kidney (BHK) cells on-line. In this work the OWLS is shown to be a promising tool to study the adhesion, morphology and metabolic state of fibroblasts in real time. A new design of the measuring chamber allowed simultaneous observation by phase-contrast microscopy and made the adsorbed cell density controlable and reproducible. The OWLS signal correlated quantitatively with the contact-area between the fibroblasts and the waveguide. The OWLS signals for adhesion and spreading of three different fibroblast cell lines were in good agreement with their morphology identified by phase-contrast microscopy. The cell adhesion and cell shape changes were examined in three scenarios: (a) serum-induced spreading of the surface attached fibroblasts was followed until it was completed, and the OWLS signal remained constant for over 12 h; (b) the fully spread cells were exposed to the microtubuli-disrupting colchicine and a decrease of the OWLS signal was monitored; (c) in a similar experiment with benzalkonium chloride, a strong skin irritant, a concentration-dependent response of the signal was found. The results show the strength of the OWLS method for monitoring the adhesion behavior of anchorage-dependent cells such as fibroblasts. It has a great potential as a whole-cell biosensor for high throughput screening in toxicology.     

Monitoring cell concentration and activity by multiple excitation fluorometry.

Four key cellular metabolic fluorophores--tryptophan, pyridoxine, NAD(P)H, and riboflavin--were monitored on-line by a multiple excitation fluorometric system (MEFS) and a modified SLM 8000C scanning spectrofluorometer in three model yeast fermentation systems--bakers' yeast growing on glucose, Candida utilis growing on ethanol, and Saccharomyces cerevisiae RTY110/pRB58 growing on glucose. The measured fluorescence signals were compared with cell concentration, protein concentration, and cellular activity. The results indicate that the behavior and fluorescence intensity of various fluorophores differ in the various fermentation systems. Tryptophan fluorescence is the best signal for the monitoring of cell concentration in bakers' yeast and C. utilis fermentations. Pyridoxine fluoresce is the best signal for the monitoring of cell concentration in the S. cerevisiae RTY110/pRB58 fermentation. In bakers' yeast fermentations the pyridoxine fluorescence signal can be used to monitor cellular activity. The NAD(P)H fluorescence signal is a good indicator of cellular activity in the C. utilis fermentation. For this fermentation NAD(P)H fluorescence can be used to control ethanol feeding in a fed-batch process.     

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.     

Development of an on-line monitoring system of human keratinocyte growth by image analysis and its application to bioreactor culture

Human keratinocytes were cultured in serum-free medium for the purpose of on-line cell growth monitoring by image analysis. The validity of a process using a newly developed video microscopy system with image analysis for growth-rate monitoring in real time was verified by the measurement of the degree of confluence of keratinocytes in T-flasks and Petriperm dishes. The growth rate of keratinocytes was calculated subsequently from the linear relationship between average degree of confluence and cell concentration. This technique was applied to the culture in the bioreactor "KERATOR" in which a special video microscopy system using a CCD camera was built. The cell concentration evaluated by image analysis agreed well with that evaluated by conventional direct cell counting after enzymatic digestion, and the on-line monitoring of the specific growth rate allowed identification of both lag- and exponential-growth phases of the culture.     

Implementation of a thermal biosensor in a process environment: on-line monitoring of penicillin V in production-scale fermentations.

The production of penicillin V was monitored in 0.5 m3 and 160 m3 bioreactors. The thermal biosensor was an enzyme thermistor modified for split-flow analysis. The heat signal generated in the enzyme column was corrected for any nonspecific heat with the use of an identical but inactive reference column. The on-line monitoring was performed in the fermentation pilot plant and in a fermentation plant of Novo Nordisk A/S. Immobilized beta-lactamase was used to monitor three consecutive 0.5 m3 penicillin fermentations. Broth samples were continuously filtered through a tangential flow filtration unit in a sterile external loop. The on-line penicillin V values were 10% higher than those obtained by off-line HPLC analysis. Alternatively a polypropylene filtration probe was inserted into a 160 m3 bioreactor and samples were withdrawn at 0.5 ml/min. The same experiments were repeated with purified and immobilized penicillin V acylase. The on-line penicillin V values obtained with this enzyme correlated very well with those from HPLC analysis. The on-line monitoring was controlled and analysed by a software program written in Labtech Notebook.     

Pilot-scale culture ofCoffea arabica in a novel loop fluidised bed reactor

A novel bubble free loop fluidized bed reactor for plant cell cultures was developed and tested usingCoffea arabica as a model cell line. The effects of main operational parameters like morphology and size of inoculum, oxygen supply as well as recirculation of sparingly soluble gases on cell growth and alkaloid production rates in this reactor were studied and the results were compared with standard shake flask experiments. By on-line monitoring of biomass and oxygen uptake rates the main kinetic parameters for cell growth and alkaloid production were evaluated. It was demonstrated that the novel reactor is easy to run and is particularly adequate for measuring kinetic parameters necessary for scale up.     

On-line determination of intracellular beta-galactosidase activity in recombinant Escherichia coli using flow injection analysis (FIA).

A flow injection analysis (FIA) system was developed for the determination of cytoplasmic beta-galactosidase activity in recombinant Escherichia coli. The FIA system and its application for on-line monitoring of beta-galactosidase production during cultivation of recombinant E. coli in a 60-l airlift tower loop reactor is described. The results demonstrate that an FIA assay in conjunction with a cell disintegration step can be applied successfully for on-line monitoring of intracellular protein formation.     

Cole–Cole, linear and multivariate modeling of capacitance data for on-line monitoring of biomass

This work evaluates three techniques of calibrating capacitance (dielectric) spectrometers used for on-line monitoring of biomass: modeling of cell properties using the theoretical Cole–Cole equation, linear regression of dual-frequency capacitance measurements on biomass concentration, and multivariate (PLS) modeling of scanning dielectric spectra. The performance and robustness of each technique is assessed during a sequence of validation batches in two experimental settings of differing signal noise. In more noisy conditions, the Cole–Cole model had significantly higher biomass concentration prediction errors than the linear and multivariate models. The PLS model was the most robust in handling signal noise. In less noisy conditions, the three models performed similarly. Estimates of the mean cell size were done additionally using the Cole–Cole and PLS models, the latter technique giving more satisfactory results.     

Optical waveguide lightmode spectroscopy (OWLS) to monitor cell proliferation quantitatively

The use of microscopic observations used for in situ monitoring of cell proliferation in the production of epidermal autografts is not satisfactory. In particular, the identification of the projected cell area from microscopic pictures by image analysis (IA) depends on intensity edges and level of contrasts and is thus limited to subconfluent cultures. Some of these problems can be solved by using optical waveguide lightmode spectroscopy (OWLS), which measures the effective refractive index of a thin layer above an Si(Ti)O(2) waveguide surface. In this study the use of OWLS to monitor cell adhesion, spreading, and growth was studied. The sensitivity of the method was investigated by using three different cell lines, two fibroblasts and one hepatoma cell line. Cell proliferation of two strains of fibroblasts and hepatoma cells was monitored up to 2 days with the OWLS. In parallel, cell density was determined at different time points microscopically using an additional window in the measuring chamber. The cell density of fully spread cells ( approximately 4 h after attachment) was found to be proportional to the OWLS signal. In long-term cultures the influence of the cell density from single cells to confluent cell cultures upon the OWLS signal was investigated. The exponentially growing number of hepatoma resulted in a linear increase of the sensor signal. Due to this and to the fact that the proliferating cells exhibit contact inhibition, it was concluded that the cell contact area must decrease exponentially. The results show the strength of OWLS for monitoring the adhesion and proliferation of anchorage-dependent cells in applications where an on-line indicator of the total biomass is needed. Additionally, OWLS provides metabolic information through detection of the cell mass in close contact with the waveguide.     

Comparison of sickle cell hemoglobin gelation kinetics measured by NMR and optical methods.

We describe a technique for monitoring the kinetics of sickle cell hemoglobin gelation by observing the change in the amplitude and linewidth of the water proton magnetic resonance. The resulting kinetic progress curves are very similar to those obtained by optical birefringence and turbidity methods. The curves consist of a delay, followed by a rapidly accelerating signal change which terminates quickly. From a study of the temperature dependence of the delay time, it is shown that all three techniques see the onset of gelation simultaneously. The origin of the change in physical properties upon gelation is briefly discussed in relation to the component steps of the reaction.