Analysis of pH-stat continuous cultivation and the stability of the mixed fermentation in continuous yogurt production

A pH-stat fermentor is a continuous cultivator in which the feed rate is controlled to maintain a constant pH, i.e., end-product acid concentration. This fermentor has application to the continuous cultivation of lactic acid-producing organisms in milk-based media. The equations describing the operation of this fermentor are developed. It is shown that, where the limiting substrate is the carbon and energy source, the operation of the fermentor is essentially equivalent to that of a turbidostat. In contrast to this, where the carbon and energy source is in excess and growth is limited by another substrate, pH-state fermentation is stable both in regions of substrate excess, where D = μ_max, comparable with turbidostat operation, and substrate limitation where D < μ_max, comparable with chemostat operation. These conditions are met in milk-based media. An analysis is presented, allowing the prediction of the degree of substrate limitation, cell density, and dilution rate in a pH-stat fermentor from batch-growth kinetics. This was confirmed using experimental data for the growth of Streptococcus thermophilus TS2 and Lactobacillus LB1 in skim milk. Stable simultaneous growth of two organisms in continuous culture occurs if their growth rates are determined by separate conditions, so that, at steady state, their growth rqtes are separately madeequal to the dilution rate. It is then predicted, and confirmed by experiment, that a mixed culture of S. thermophilus TS2 and L. bulgaricus LB1 in a pH-stat continuous fermentor in yogurt mix at pH 5.5 would be stable with the growth of L. bulgaricus being substrate unlimited and the fermentor operting with D = μ_max for L. bulgaricus LB1, and the growth of S. thermophilus TS2 being substrate limited so that its growth rate is equal to the existing dilution rate. Finally, it is predicted and confirmed by experiment that if the conditions are altered so that the growth of S. thermophilus TS2 is substrate unlimited the stable association is broken down, the fermentor operates with D approaching μ_max for S. thermophilus TS2, and L. bulgaricus LB1 is washed out to the level maintained by wall growth.     

Optimization of process parameters for the production of carbonyl reductase by <Emphasis Type="Italic">Candida viswanathii</Emphasis> in a laboratory-scale fermentor

The effect of pH, aeration and mixing on the growth and production of carbonyl reductase by Candida viswanathii was investigated in a 6.6-l fermentor. Controlling the pH at 8.0 had a very significant effect on the enzyme production. Aeration and agitation influenced the dissolved oxygen concentration which in turn affected growth as well as enzyme production. A maximum carbonyl reductase activity (53 Umg⁻¹) was attained in 24 h under the optimal cultivation conditions of controlled pH at 8.0, aeration rate 1 vvm and an agitation speed of 250 rpm at 25°C. The enzyme activity was twice as high (56 Umg⁻¹) in the fermentor as compared to a shake flask. Further, the duration of growth and enzyme production in the fermentor was shortened. Cells cultivated under the optimized conditions were used for the preparative scale reduction of N, N-dimethyl-(3-keto)-2-thienyl-propanamine to (S)-N, N-dimethyl-(3-hydroxy)-2-thienyl-propanamine, a key intermediate in the production of the important antidepressant drug (S)-duloxetine.     

Mechanism of uptake of liquid hydrocarbons by microorganisms

Growth rates of Candida tropicalis were studied in two different fermentors. One was the ordinary shaker flask containing both the aqueous culture medium and liquid hydrocarbons. The other was a specially designed rotating disk-type fermentor containing only the aqueous culture medium, into which vapors of n-paraffins from C₆ to C₁₈ were supplied continuously without forming the liquid hydrocarbon phase. The specific growth rates of Candida tropicalis in the rotating disk fermentor, under such conditions that supply of hydrocarbon vapor was sufficient, showed good agreement with those in the shaker flask. This seems to indicate that hydrocarbon uptake by Candida tropicals by direct contact with liquid hydrocarbon is negligible.     

Continuous production of extracellular protease by Bacillus subtilis in a two-stage fermentor

Growth and protease production of Bacillus subtilis in semisynthetic and synthetic media were studied in batch culture and in a two-stage, laboratory scale, continuous fermentor. The amount, of extracellular protease production was measured under specific growth conditions in both stages of the ferment or. At the dilution rates employed, the cells in the first stage of the ferment or produced negligible quantities of protease, and the culture primarily functioned as a continuous inoculum for the second stage of the fermentor. The culture effluent from the second stage of the fermentor contained extracellular protease, on the average, equal to 60 per cent, of the activity that had been found in the supernatant of a 48-hr batch culture grown in a medium having the same composition as that in the continuous fermentor. Extracellular protease was produced in semisynthetic medium by B. subtilis in the two-stage fermentor for as long as 20 days without culture degeneration. Additional studies indicated that continuous protease production could also be achieved in a synthetic medium. The RNA/ protein ratios of cells grown in semisynthetic medium in batch culture and in each stage of the two-stage fermentor were examined. There was a positive correlation between the amount of protease produced by the cells and their RNA/ protein ratio. Techniques employed for continuous production of protease by B. subtilis and the potential use of the method for investigating the control of secondary metabolite synthesis are discussed.     

Continuous hydrocarbon fermentation with colloidal emulsion feed. A kinetic model for two-liquid phase culture

Candida tropicalis was cultured in a chemostat-type fermentor with n-hexadecane, dispersed in water as submicron droplets, as the only carbon substrate. The emulsion as well as the aqueous medium were fed continuously into the fermentor. A Monod-type equation can correlate the specific group rate in the continuous fermentor with the concentration of submicron droplets. The same equation can also be fitted to the data for the conventional-type batch culture in the same fermentor in which an oil phase as well as an aqueous phase existed, if the hydrocarbon concentration in the aqueous phase excluding oil drops is employed as the substrate concentration. This demonstrates that Candida tropicalis takes up only submicron droplets of n-hexadecane as the carbon substrate.     

Production of polygalacturonase byByssochlamys fulva

Summary Byssochlamys fulva was grown in two fermentation media using shake flasks, stirred fermentor and disc fermentor under conditions to give maximum production of pectolytic enzymes. Only polygalacturonase activity was detected in the culture filtrates during all fermentations. In all production conditions studied, no evidence of pectin methylesterase, pectin lyase, cellulase or proteinase activities were found. The maximum polygalacturonase activity (4.5 units/ml) was achieved when the microorganism was grown on medium II in shake flasks at pH 4.0–4.5 and 30°C after 12 days of fermentation.     

Effect of interstage mixing in multistage culture systems on continuous biomass production

The significance of the interstage mixing on important process parameters of biomass production was studied. The experiments were performed in a multistage tower fermentor and in fermentors in series. The interstage mixing effect can be evaluated under conditions of geometrical similarity, identity of oxygen transfer rate, and identity of dilution rate per stage in the individual stages of both culture systems. Candida utilis was cultivated on a synthetic medium with ethanol as the sole carbon and energy source in the concentration range 10–100 g/liter. Dilution rate, temperature, and pH in each stage of both culture systems were kept constant. It was demonstrated that in the multistage tower fermentor the definite backflow which ensures the permanent reinoculation by adapted cells significantly decreases the inhibitory effect of higher ethanol concentrations on the cell growth and on the rate of ethanol utilization.     

Scale-up of purine nucleoside fermentation from a shaking flask to a stirred-tank fermentor

Scaling-up purine nucleoside fermentation by a mutant strain of Bacillus subtilis from a shaking flask to a stirred-tank fermentor was attempted. The dimensions and the operating conditions of the stirred tank were determined in order to satisfy the optimum conditions of O₂ transfer and power consumption per unit volume for the shaking flask. When the purine nucleoside fermentation was carried out in the stirred-tank fermentor under these conditions, in which the temperature simulated that in the shaking flask, the total amount of purine nucleosides produced was almost the same as that in the shaking flask, but the accumulation ratio of guanosine to total nucleotides was different from that in the flask. Since urea could not be utilized so efficiently in the stirred-tank fermentor, the NH^p+ _f4 concentration and the pH of the culture broth were lower than those in the shaking-flask culture during fermentation. The activity of inosine monosphosphate dehydrogenase and the accumulation ratio were significantly affected by the NH^p+ _f4 concentration. When the pH of the stirred-tank culture was maintained at 6.9 by ammonia water to keep the NH^p+ _f4 level higher, the ratio was improved to the same level as that observed in the shaking-flask culture. The fermentation heat calculated from the shaking-flask data and its pattern of change were similar to those in the stirred-tank fermentor. Correspondence to: Y. Sumino     

Production of single cell protein from rice polishings using Candida utilis

Microbial protein was produced from defatted rice polishings using Candida utilis in shake-flasks and a 14-l fermentor to optimize fermentation conditions before producing biomass in a 50-l fermentor. The organism supported maximum values of 0.224 h⁻¹, 0.94, 1.35, 1.75, 2.12 g l⁻¹ h⁻¹, 0.62 g cells g⁻¹ substrate utilized and 0.38 g g⁻¹ for specific growth rate, true protein productivity, crude protein productivity, cell mass productivity, substrate consumption rate, cell yield, crude protein yield, respectively in 50-l fermentor studies using optimized cultural conditions. Maximum values compared favourably or were superior to published data in literature. The biomass protein in the 50-l fermentor contained 22.3, 27.8, 19.2, 9.5, 38.12, 8.5 and 0.27% true protein, crude protein, crude fibre, ash, carbon, cellulose and RNA content, respectively. The dried biomass showed a gross metabolizable energy value of 2678 kcal kg⁻¹ and contained all essential and non-essential amino acids. Yeast biomass as animal feed may replace expensive feed ingredients currently being used in poultry feed and may improve the economics of feed produced in countries like Pakistan. This revised version was published online in August 2006 with corrections to the Cover Date.     

Spore production ofPenicillium roqueforti in fermentors filled with buckwheat seeds: batch and semi-continuous cultivation

Summary The behaviour of a drum fermentor and a column fermentor during the sporulation ofPenicillium roqueforti on buckwheat seeds is presented. The main problem encountered during the course of a cultivation is the free water released (about 0.1 ml/g dry matter) which must be removed from the medium. The rotation of the drum fermentor may disturb the growth and the sporulation. The column fermentor thus represents the best way to perform batch cultivation of the fungus: 10⁹ external spores/g dry matter are obtained.Semi-continous cultivation, with sequential emptying and filling, is performed in 1-liter bottles. This kind of cultivation may give a maximal average productivity close to 9.2·10⁶ external spores/g dry matter per hour. A drum fermentor, rotading only when emptying and filling, could represent an alternative to perform this kind of cultivation.     

Large-scale production of anthocyanin by Aralia cordata cell suspension cultures

The suspension culture of high anthocyanin-producing Aralia cordata cell lines, which grow and produce anthocyanin without light irradation, was scaled up from flasks to a 10-1 glass jar fermentor, a 95-1 stainless steel jar fermentor, and finally a 500-l pilot-scale jar fermentor. By the administration of CO₂, cell damage was completely prevented and the anthocyanin content was kept as high as 7.0–17.2% (w/w) of the dried cells. In one of the operations of the 500-l jar fermentor, cells were cultivated for 16 days. During this operation, cell mass was increased by more than 26 times (cell yield: 69.2 kg fresh wt.) and the amount of anthocyanin increased by more than 55 times (anthocyanin yield: 545 g, anthocyanin content: 17.2% of the dried cells). Correspondence to: Y. Kobayashi     

Ethanol production in a hollow fiber bioreactor using Saccharomyces cerevisiae

Summary A new approach for continuous production of ethanol was developed using a Hollow fiber fermentor (HFF). Saccharomyces cerevisiae cells were packed into the shell-side of a hollow fiber module. Using 100 g/l glucose in the feed gave an optimum ethanol productivity, based on total HFF volume, of 40 g ethanol/l/h at a dilution rate of 3.0 h^-1. Under these conditions, glucose utilization was 30%. However, at 85% glucose utilization the productivity was 10 g ethanol/l/h. This compares to batch fermentor productivity of 2.1 g ethanol/l/h at 100% glucose utilization.     

Kojic acid production byAspergillus flavus using gelatinized and hydrolyzed sago starch as carbon sources

Direct conversion of gelatinized sago starch into kojic acid byAspergillus flavus strain having amylolytic enzymes was carried out at two different scales of submerged batch fermentation in a 250-mL shake flask and in a 50-L stirred-tank fermentor. For comparison, fermentations were also carried out using glucose and glucose hydrolyzate from enzymic hydrolysis of sago starch as carbon sources. During kojic acid fermentation of starch, starch was first hydrolyzed to glucose by the action of α-amylase and glucoamylase during active growth phase. The glucose remaining during the production phase (non-growing phase) was then converted to kojic acid. Kojic acid production (23.5g/L) using 100 g/L sago starch in a shake flask was comparable to fermentation of glucose (31.5 g/L) and glucose hydrolyzate (27.9 g/L) but in the 50-L fermentor was greatly reduced due to non-optimal aeration conditions. Kojic acid production using glucose was higher in the 50-L fermentor than in the shake flask.     

产GL-7-ACA酰化酶重组菌的构建及高表达研究

戊二酰基-7-氨基头孢烷酸(GL-7-ACA)酰化酶是7-氨基头孢烷酸(7-ACA)两步酶法生产中的关键酶。成功构建组成型表达的产GL-7-ACA酰化酶重组大肠杆菌JM105/pMKC-ACY,并对其高表达条件进行了研究,得到了组成简单、廉价的国产培养基配方及操作简便、易于实现工业化的发酵工艺。在优化条件下,上罐补料高密度发酵的酶活高达6668.9U/L,是优化前的12.4倍,产率最高可达275.5U/(L.h),达到了工业生产的要求。     

Changes in steady state on introduction of a Lactobacillus contaminant to a continuous culture ethanol fermentation

Lactobacillus paracasei was introduced as a contaminant into a multistage continuous culture ethanol fermentation system at ratios of 1:100, 1:1, and 70:1 with Saccharomyces cerevisiae, but failed to overtake the yeast. None of the inoculation ratios allowed L. paracasei to affect S. cerevisiae in the first fermentor in the multistage system. S. cerevisiae remained constant at ∼3×10⁷ CFU/ml regardless of the bacterial inoculation level, and even at the 70:1 inoculation ratio, glucose, ethanol, and lactic acid concentrations did not change from the steady-state concentrations seen before bacterial inoculation. However, L. paracasei decreased steadily from its initial inoculation level of ∼2.2×10⁹ CFU/ml and stabilized at 3.7×10⁵ CFU/ml after 10 days of steady-state operation. Both organisms then persisted in the multistage system at an approximate L. paracasei/S. cerevisiae ratio of 1:100 which confirms that, in continuous fuel ethanol production, it would be difficult to eliminate this bacterium. Only when the pH was controlled at 6.0 in fermentor 1 (F1) were changes seen which would affect the multistage system. Ethanol concentration then decreased by 44% after 4 days of pH-controlled operation. This coincided with an increase in L. paracasei to >10¹⁰ CFU/ml, and a 4× increase in lactic acid concentration to 20 g/l. When the clarified contents from other fermentors (F2–F5) in the multistage system were used as growth media, L. paracasei was not able to grow in batch culture. This indicated that the first fermentor in the multistage system was the only fermentor capable of supporting the growth of L. paracasei under the described conditions. Journal of Industrial Microbiology & Biotechnology (2001) 27, 39–45. Received 26 February 2001/ Accepted in revised form 29 May 2001     

Citrate production from hydrocarbons by use of a nonsterile,semicontinuous cell recycle system

In order to minimize product toxicity, decrease fermentation cost, prolong the effective production phase, and shorten the lag phase before production in the citrate-hydrocarbon fermentation by Candida lipolytica ATCC 8661, the use of a nonsterile semicontinuous cell recycle system was investigated. Model experiments demonstrated that portions of the fermentor broth could periodically be removed and centrifuged under nonaseptic conditions with the cells being added to fresh medium and returned to the fermentor. Citrate production continued, however with repeated semicontinuous cell recycle, acid production gradually decreased. It was postulated that this decrease could be attributed largely to physiological trauma and that a truly continuous cell recycle system would minimize these effects and permit maintenance of higher citrate production rates.     

An experimental study of acid production rate controlled operations of a continuous fermentor

The efficacy of acid production rate (APR) controlled operations of a continuous fermentor supporting the growth of a methylotroph, L3, was experimentally examined. Direct digital control of pH at a constant value allowed for on-line estimation of APR during the fermentation. Two types of APR controlled operations were studied. In the first type of operation, the APR was controlled at a constant value according to a predetermined program by manipulating the feed flow rate to the fermentor. Such an operation effectively stabilized the cell mass productivity of a continuous fermentor subjected to disturbances in the feed nutrient concentration. It resulted in a near complete conversion of methanol to yield a cell mass product with very low amounts of unutilized methanol at both steady state and transient fermentation situations. In the second type of operation, the feed flow rate was manipulated to optimize the steady state value of APR during the fermentation. This method shows promise for on-line steady state optimization of cell mass productivity in a continuous fermentor.     

Acetic acid production by Acetobacter aceti in a silicone tube bioreactor

Summary Continuous acetic acid fermentation was carried out using a column reactor, in which 20 to 200 thin silicone tubes (0.33 mm in outer diameter) were packed to supply oxygen by permeation. The highest value of volumetric oxygen transfer coefficient determined by the sulfite oxidation method was 2,860 h^–1, which was comparable to that of a well agitated and aerated fermentor. The maximum production rate of acetic acid by the bacterial films of Acetobacter aceti M7 grown on the shell-side surface of the tubes was 38.0 g/lh at an acetic acid concentration of 44.5 g/l. This was 29 times that of a continuous culture using a jar fermentor.     

Production of yeast-lytic enzymes by Cytophaga species in batch culture

The conditions for culture storage, inoculum preparation, and growth of a Cytophaga species, constitutive with respect to yeast-lytic enzymes, have been established in shake-flask studies and in 5 liter fermentor experiments. A low cost medium was adopted for 900 liter-scale fermentation and gave an enzyme activity in the fermentation broth somewhat greater than the comparable laboratory-scale one.     

Production of C<Subscript>35</Subscript> isoprenoids depends on H<Subscript>2</Subscript> availability during cultivation of the hyperthermophile<Emphasis Type="Italic"> Methanococcus jannaschii</Emphasis>

A series of five progressively saturated C₃₅ isoprenoids has been identified in cell-free extracts of the deep-sea methanogen Methanococcus jannaschii. Production and relative abundance of the isoprenoids were dependent on culture conditions; significant production occurred in a 16-l fermentor (12-l working volume) and a 2.5-l fermentor (2-l working volume) but could not be duplicated in serum bottles. Several factors were investigated and shown not to account for the different production levels, including medium composition, pH, and temperature. However, the interphase mass transfer rate was shown to significantly affect the production of C₃₅ isoprenoids in a fermentor. The structures of the novel isoprenoids were confirmed by hydrogenation reactions and mass spectra of the isoprenoids. Indirect evidence based on genomics and mass spectrometry data implicates head-to-head condensation of farnesyl pyrophosphate (C₁₅) with geranylgeranyl pyrophosphate (C₂₀) as the mechanism for C₃₅ synthesis.Communicated by J. WiegelB.P. Manquin and J.A. Morgan contributed equally to this work.