High bioreactor production and emulsifying activity of an unusual exopolymer by Chromohalobacter canadensis 28

Unusual composition of an exopolymer (EP) from an obligate halophilic bacterium Chromohalobacter canadensis 28 has triggered an interest in development of an effective bioreactor process for its production. Its synthesis was investigated in 2‐L bioreactor at agitation speeds at interval 600‐1000 rpm, at a constant air flow rate of 0.5 vvm; aeration rates of 0.5, 1.0, and 1.5 vvm were tested at constant agitation rate of 900 rpm. EP production was affected by both, agitation and aeration. As a result twofold increase of EP yield was observed and additionally increased up to 3.08 mg/mL in a presence of surfactants. For effective scale‐up of bioreactors mass transfer parameters were estimated and lowest values of K_La obtained for the highest productivity fermentation was established. Emulsification activity of EP exceeded that of trade hydrocolloids xanthan, guar gum, and cellulose. A good synergism between EP and commercial cellulose proved its potential exploration as an enhancer of emulsifying properties of trade emulsions. A pronounced lipophilic effect of EP was established toward olive oil and liquid paraffin. Cultivation of human keratinocyte cells (HaCaT) with crude EP and purified γ‐polyglutamic acid (PGA) showed higher viability than control group.     

Real-time dissolved carbon dioxide monitoring II: Surface aeration intensification for efficient CO2 removal in shake flasks and mini-bioreactors leads to superior growth and recombinant protein yields

Mass transfer is known to play a critical role in bioprocess performance and henceforth monitoring dissolved O₂ (DO) and dissolved CO₂ (dCO₂) is of paramount importance. At bioreactor level these parameters can be monitored online and can be controlled by sparging air/oxygen or stirrer speed. However, traditional small-scale systems such as shake flasks lack real time monitoring and also employ only surface aeration with additional diffusion limitations imposed by the culture plug. Here we present implementation of intensifying surface aeration by sparging air in the headspace of the reaction vessel and real-time monitoring of DO and dCO₂ in the bioprocesses to evaluate the impact of intensified surface aeration. We observed that sparging air in the headspace allowed us to keep dCO₂ at low level, which significantly improved not only biomass growth but also protein yield. We expect that implementing such controlled smart shake flasks can minimize the process development gap which currently exists in shake flask level and bioreactor level results.     

Continuous plug-flow bioreactor: experimental testing with Pseudomonas putida culture grown on benzoate

The goals of this work were to test the feasibility of a continuous plug-flow (PF) bioreactor and to compare the growth in the PF bioreactor to that in a batch bioreactor. A culture of Pseudomonas putida was pumped through a tube made of Teflon with varying residence times. The culture was aerated by pumping of air simultaneously with liquid medium to provide air bubbles along the tubular culture. When the residence time in the PF bioreactor was greater than the time needed to reach the stationary phase in batch mode, the maximum biomass density reached in PF mode was the same as the maximum density reached in the batch bioreactor, and benzoate (the only carbon and energy source) was completely consumed. The drawbacks for practical application of PF were found to be fluctuations of cell concentration in the outflow cultural liquid due to cell aggregation, significant cell adhesion to the inner wall of Teflon tubing, and inadequate aeration.     

Monitoring cellular state transitions in a production-scale CHO-cell process using an electronic nose

An electronic nose is used to monitor the bioreactor off-gas composition in perfused cultivations of a CHO-cell line producing recombinant human blood coagulation factor VIII. The applicability of the electronic nose for monitoring cellular state transitions and process control is explained. It is shown that the instrument can reveal characteristic process states related to product and lactate formation, and detect microbial infections in a very early stage of the infection. The visualization of ideal process conditions is realized by using principal component analysis (PCA) and the on-line applicability of this method is outlined. The results illustrate the potential of the electronic nose as on-line sensor for ensuring product and process quality in production-scale bioprocesses.     

Formation of ethyl acetate by Kluyveromyces marxianus on whey: Influence of aeration and inhibition of yeast growth by ethyl acetate

The ability of the yeast Kluyveromyces marxianus to convert lactose into ethyl acetate offers good opportunities for the economical reuse of whey. The formation of ethyl acetate as a bulk product depends on aerobic conditions. Aeration of the bioreactor results in discharge of the volatile ester with the exhaust gas that allows its process‐integrated recovery. The influence of aeration (varied from 10 to 50 L/h) was investigated during batch cultivation of K. marxianus DSM 5422 in 0.6 L whey‐borne medium using a stirred reactor. With lower aeration rates, the ester accumulated in the bioreactor and reached higher concentrations in the culture medium and the off gas. A high ester concentration in the gas phase is considered beneficial for ester recovery from the gas, while a high ester concentration in the medium inhibited yeast growth and slowed down the process. To further investigate this effect, the inhibition of growth by ethyl acetate was studied in a sealed cultivation system. Here, increasing ester concentrations caused a nearly linear decrease of the growth rate with complete inhibition at concentrations greater than 17 g/L ethyl acetate. Both the cultivation process and the growth rate depending on ethyl acetate were described by mathematical models. The simulated processes agreed well with the measured data.     

Scaleup of ajmalicine production by plant cell cultures of Catharanthus roseus

The effect of scaleup on he production of ajmalicine by a Catharanthus roseus cell suspension culture in a selected induction medium were studied. In preliminary experiments it was observed that the culture turned brown and the production was inhibited upon transfer from a shake flask to a stirred bioreactor with forced aeration. Two factors were recognized as the potential origin of the differences between shake flask and bioreactor cultures: gas composition and mechanical shear forces. These factors were studied separately.By recirculating a large part of the exhaust gas, a comparable gas regime was obtained in a bioreactor as occurred in a shake flask cultures. This resulted in the absence of browning and a similar pattern of ajmalicine production as observed in shake flasks. The effect of shear forces could not be demonstrated. However, the experiments showed that the culture may be very sensitive to liquid phase concentrations of gaseous compounds. The effects of k(L)a, aeration rate, CO(2) production rate, and influent gas phase CO(2) concentration on the liquid phase CO(2) concentration are discussed. (c) 1993 John Wiley & Sons, Inc.     

Simultaneous amylase production,raw cassava starch hydrolysis and ethanol production by immobilized Aspergillus awamori and Saccharomyces cerevisiae in a novel alternating liquid phase–air phase system

As a solution to the problems of mass transfer limitation in submerged cultures and scale up of solid-state/liquid-surface cultures, an alternating liquid phase–air phase bioreactor was developed. It consisted of a bioreactor equipped with a siphon system and a reservoir. Aspergillus awamori was immobilized in loofa sponge inside the bioreactor and culture broth was pumped from the reservoir into the bioreactor. Each time the culture broth level reached a critical level, the broth automatically siphoned back into the reservoir. Thus the immobilized cells were alternatingly submerged and exposed to air. The duration of each phase was controlled by the pumping rate and with an on-off timer. During amylase production from soluble starch and raw cassava starch, the optima ratios of the liquid to air phases were 12 h : 12 h and 3 h : 6 h respectively. Saccharomyces cerevisiae IR2 was immobilized in the reservoir and the system was used for simultaneous amylase production, hydrolysis and ethanol production from raw cassava starch. The process was very stable for more than 7 batches with high ethanol yield of 0.46 g-ethanol/g-starch and productivity of 1.73 g-ethanol/L/h. These values are high, the system can be scaled up, and thus it has many potential applications.     

Acetylene inhibition technique underestimates in situ denitrification rates in intact cores of freshwater sediment

Abstract Denitrification in intact sediment cores was measured by the acetylene inhibition technique and compared with the nitrate flux between water and sediment. Less than half of the nitrate-N consumed by the sediment could be recovered as nitrous oxide-N. The low recovery rate of nitrous oxide from intact sediment cores indicated losses of nitrous oxide by diffusion down to nitrate-free sediment layers, where reduction of nitrous oxide may take place. In sediment slurries 100% of nitrate-N could be recovered as nitrous oxide-N as long as the nitrate concentration in the liquid phase was above 10 μM. Nitrous oxide added to nitrate-free sediment slurries was reduced regardless of whether acetylene was present or not. Therefore denitrification may be significantly underestimated by this method.     

Customized design of electronic noses placed on top of air-lift bioreactors for in situ monitoring the off-gas patterns

A specially designed electronic nose was coupled to an air-lift bioreactor in order to perform on-line monitoring of released vapors. The sensor array was placed at the top of the bioreactor sensing the headspace in equilibrium with the evolving liquor at any time without the need of aspiration and pumping of gases into a separated sensor chamber. The device was applied to follow the off-gas of a bioreactor with Acidithiobacillus thiooxidans grown on beds of elemental sulfur under aerobic conditions. Evolution was monitored by acid titration, pH and optical density measurements. The electronic nose was capable to differentiate each day of reactor evolution since inoculation within periods marked off culture medium replacements using multivariate data analysis. Excellent discrimination was obtained indicating the potentiality for on-line monitoring in non-perturbed bioreactors. The prospects for electronic nose/bioreactor merging are valuable for whatever the bacterial strain or consortium used in terms of scent markers to monitor biochemical processes.     

Biodegradation of the Water‐Soluble Gasoline Components in a Novel Hybrid Bioreactor

A novel hybrid bioreactor was designed to remove volatile organic compounds from water contaminated with water‐soluble gasoline components, and the performance of this new bioreactor was investigated. It was composed of two biotrickling filter sections and one biofilter section. The liquid phase pollutants were removed by a mixed culture in the biotrickling filter sections and the gas phase pollutants stripped by air injection in the biofilter section. The specific rates of chemical oxygen demand (COD) removal obtained in the reactor were directly proportional to the pollutant‐loading rate. A stable operation of the hybrid bioreactor was attained for long periods of time. The bioreactor had the potential to simultaneously treat a complex mixture of volatile organic compounds, e.g., those present in the water‐soluble fraction of gasoline, as well as the capacity to readily adapt to changing operational conditions, such as an increased contaminant loading, and variations in the airflow rate.     

Biomanufacturing process analytical technology (PAT) application for downstream processing: Using dissolved oxygen as an indicator of product quality for a protein refolding reaction

Process analytical technology (PAT) is an initiative from the US FDA combining analytical and statistical tools to improve manufacturing operations and ensure regulatory compliance. This work describes the use of a continuous monitoring system for a protein refolding reaction to provide consistency in product quality and process performance across batches. A small‐scale bioreactor (3 L) is used to understand the impact of aeration for refolding recombinant human vascular endothelial growth factor (rhVEGF) in a reducing environment. A reverse‐phase HPLC assay is used to assess product quality. The goal in understanding the oxygen needs of the reaction and its impact to quality, is to make a product that is efficiently refolded to its native and active form with minimum oxidative degradation from batch to batch. Because this refolding process is heavily dependent on oxygen, the % dissolved oxygen (DO) profile is explored as a PAT tool to regulate process performance at commercial manufacturing scale. A dynamic gassing out approach using constant mass transfer (k_La) is used for scale‐up of the aeration parameters to manufacturing scale tanks (2,000 L, 15,000 L). The resulting DO profiles of the refolding reaction show similar trends across scales and these are analyzed using rpHPLC. The desired product quality attributes are then achieved through alternating air and nitrogen sparging triggered by changes in the monitored DO profile. This approach mitigates the impact of differences in equipment or feedstock components between runs, and is directly inline with the key goal of PAT to “actively manage process variability using a knowledge‐based approach.” Biotechnol. Bioeng. 2009; 104: 340–351 © 2009 Wiley Periodicals, Inc.     

Turning, compacting and the addition of water as factors affecting gaseous emissions in farm manure composting

Composting allows simple management of animal manure but excessive aeration can increase emissions of polluting gases such as ammonia or nitrous oxide. The aim of the present work was to determine the effect of three techniques--turning, compacting and the addition of water--on gaseous emissions. One ton of cattle manure and 3 tons of turkey manure were composted in two and four cells for 46 and 51 days respectively. The manure was either turned, wetted, or compacted. Emissions of carbon dioxide, water vapor, ammonia and nitrous oxide were monitored. The results show that turning did not alter the free air space. Compacting can be used specifically to reduce the water loss. A reduction of free air space by 20-60%, either by compacting or adding water (or both), reduced the ammonia and nitrous oxide emissions by 30-70%.     

Adaptive dissolved oxygen control through the glycerol feeding in a recombinant Pichia pastoris cultivation in conditions of oxygen transfer limitation

In high cell density cultivation processes the productivity is frequently constrained by the bioreactor maximum oxygen transfer capacity. The productivity can often be increased by operating the process at low dissolved oxygen concentrations close to the limitation level. This may be accomplished with a closed-loop controller that regulates the dissolved oxygen concentration by manipulating the dominant carbon source feeding rate. In this work we study this control problem in a pilot 50l bioreactor with a high cell density recombinant P. pastoris cultivation in complex media. The study focuses on the design of accurate stable adaptive controllers, with guaranteed exponential convergence and its relation with the calibration of controller parameters. Two adaptive control strategies were tested in the pilot bioreactor: a model reference adaptive controller with a linear reference model and an integral feedback controller with adaptive gain. The latter alternative proved to be more robust to errors in the measurements of the off-gas composition. Concerning the instrumentation, algorithms were derived assuming that both the dissolved oxygen tension and off-gas composition are measured on-line, but also the case of only dissolved oxygen being measured is addressed. It was verified that the measurement of off-gas composition might not improve the controller performance due to measurement and process time delays.     

Modeling of a foamed emulsion bioreactor: I. Model development and experimental validation

Recently, a new type of bioreactor for air pollution control referred to as the foamed emulsion bioreactor (FEBR) has been developed. The process relies on the emulsion of an organic phase with a suspension of an actively growing culture of pollutant-degrading microorganisms, made into a foam with the air undergoing treatment. In the current paper, a diffusion and reaction model of the FEBR is presented and discussed. The model considers the fate of the volatile pollutant in the emulsion that constitutes the liquid films of the FEBR. Oxygen limitation as well as substrate inhibition were included in the biokinetic relationships. The removal of toluene vapors served for the validation of the model. All the model parameters were determined by independent experiments or taken from the literature. The model predictions were found to be in good agreement with the experimental data and the model provided useful insights on the phenomena occurring in the FEBR. Model parametric sensitivity studies and further discussion of the factors that limit the performance of the FEBR are presented in Part 2 of this paper.     

New milliliter‐scale stirred tank bioreactors for the cultivation of mycelium forming microorganisms

A novel milliliter‐scale stirred tank bioreactor was developed for the cultivation of mycelium forming microorganisms on a 10 milliliter‐scale. A newly designed one‐sided paddle impeller is driven magnetically and rotates freely on an axis in an unbaffled reaction vessel made of polystyrene. A rotating lamella is formed which spreads out along the reactor wall. Thus an enhanced surface‐to‐volume ratio of the liquid phase is generated where oxygen is introduced via surface aeration. Volumetric oxygen transfer coefficients (k_La) > 0.15 s^?1 were measured. The fast moving liquid lamella efficiently prevents wall growth and foaming. Mean power consumption and maximum local energy dissipation were measured as function of operating conditions in the milliliter‐scale stirred tank bioreactor (V = 10 mL) and compared to a standard laboratory‐scale stirred tank bioreactor with six‐bladed Rushton turbines (V = 2,000 mL). Mean power consumption increases with increasing impeller speed and shows the same characteristics and values on both scales. The maximum local energy dissipation of the milliliter‐scale stirred tank bioreactor was reduced compared to the laboratory‐scale at the same mean volumetric power input. Hence the milliliter impeller distributes power more uniformly in the reaction medium. Based on these data a reliable and robust scale‐up of fermentation processes is possible. This was demonstrated with the cultivation of the actinomycete Streptomyces tendae on both scales. It was shown that the process performances were equivalent with regard to biomass concentration, mannitol consumption and production of the pharmaceutical relevant fungicide nikkomycin Z up to a process time of 120 h. A high parallel reproducibility was observed on the milliliter‐scale (standard deviation < 8%) with up to 48 stirred tank bioreactors operated in a magnetic inductive drive. Rheological behavior of the culture broth was measured and showed a highly viscous shear‐thinning non‐Newtonian behavior. The newly developed one‐sided paddle impellers operated in unbaffled reactors on a 10 milliliter‐scale with a magnetic inductive drive for up to 48 parallel bioreactors allows for the first time the parallel bioprocess development with mycelium forming microorganisms. This is especially important since these kinds of cultivations normally exhibit process times of 100 h and more. Thus the operation of parallel stirred tank reactors will have the potential to reduce process development times drastically. Biotechnol. Bioeng. 2010; 106: 443–451. © 2010 Wiley Periodicals, Inc.     

Enhanced system kLa and permeate flux with a ceramic membrane bioreactor

Summary A cross-flow ceramic membrane was coupled to a bioreactor to fulfil the alternate functions of process stream clarifier and primary aerator. At the same air supply rate (delivered as a back-flush), ceramic membranes provided up to 72% greater aeration than a ring-sparger located in the bioreactor. In Biol.ogical treatment of dairy food process waste, the air backflush had the additional benefit of inhibiting membrane fouling, thereby maintaining higher (by about 100%) permeate fluxes.     

Design of a large-scale surface-aerated bioreactor for biomass production using a VOC substrate

The design of a large-scale bioreactor for the production of bacterial biomass adapted to the biodegradation of volatile organic compounds was carried out. The bioreactor model used integrated the microbial kinetics and fluid dynamics described by the compartment model approach. The process conditions and kinetic parameters were adopted from the laboratory experimental study of (León, E., Seignez, C., Adler, N., Péringer, P., 1999. Growth inhibition of biomass adapted to the degradation of toluene and xylenes in mixture in a batch reactor with substrates supplied by pulses. Biodegradation 10, 245-250). The performance of the pulsed-batch stirred bioreactor under surface aeration conditions was simulated for different mixing configurations and conditions such as the impeller diameter, number of impellers, stirring speed, and oxygen pressure. The simulations were used for the cost analysis which resulted in the optimal design of the bioreactor.     

Nitrogen transformations during biological aerobic treatment of pig slurry: effect of intermittent aeration on nitrous oxide emissions

A laboratory scale aeration treatment system was built to study the fate of nitrogen during aeration of pig slurry. For each run evaluated, the nitrogen mass balance was determined including measurement of the nitrous oxide gas emissions. Intermittent aeration led to a nitrogen removal of about 53% of the total nitrogen content of the raw slurry. About 18% of the total nitrogen content of the raw slurry was emitted as N2O during aeration with an aerobic to anoxic ratio equal to 0.625. In contrast, the extension of the anoxic period (aerobic to anoxic ratio = 0.375) allowed complete denitrification and avoided N2O emissions.     

Cultivation of Mammalian Cells Using a Single-use Pneumatic Bioreactor System

Recent advances in mammalian, insect, and stem cell cultivation and scale-up have created tremendous opportunities for new therapeutics and personalized medicine innovations. However, translating these advances into therapeutic applications will require in vitro systems that allow for robust, flexible, and cost effective bioreactor systems. There are several bioreactor systems currently utilized in research and commercial settings; however, many of these systems are not optimal for establishing, expanding, and monitoring the growth of different cell types. The culture parameters most challenging to control in these systems include, minimizing hydrodynamic shear, preventing nutrient gradient formation, establishing uniform culture medium aeration, preventing microbial contamination, and monitoring and adjusting culture conditions in real-time. Using a pneumatic single-use bioreactor system, we demonstrate the assembly and operation of this novel bioreactor for mammalian cells grown on micro-carriers. This bioreactor system eliminates many of the challenges associated with currently available systems by minimizing hydrodynamic shear and nutrient gradient formation, and allowing for uniform culture medium aeration. Moreover, the bioreactor’s software allows for remote real-time monitoring and adjusting of the bioreactor run parameters. This bioreactor system also has tremendous potential for scale-up of adherent and suspension mammalian cells for production of a variety therapeutic proteins, monoclonal antibodies, stem cells, biosimilars, and vaccines.