Estimation of the rheology of glucoamylase fermentation broth from the biomass concentration and shear conditions

Fermentation broths from nine Aspergillus awamori cultivations, carried out under different agitation and aeration conditions and distinct initial substrate concentrations, were characterized using a continuous on-line rheometer. A single correlation between the consistency index (K) and the biomass concentration (X), including the agitation (N) and aeration (Q) conditions fitted the experimental data reasonably well, showing that the shear conditions imposed on the broth influence in a significant way the mycelial morphology and, therefore, the broth rheology.     

Effect of carbon source and aeration rate on broth rheology and fungal morphology during red pigment production by Paecilomyces sinclairii in a batch bioreactor

The influence of carbon source and aeration rate on fermentation broth rheology, mycelial morphology and red pigment production of Paecilomyces sinclairii was investigated in a 5-l stirred-tank bioreactor. The characteristics of P. sinclairii grown on starch and on sucrose medium were comparatively studied: the specific growth rate in sucrose medium (0.04 h(-1)) was higher than that in starch medium, whereas the specific production rate of red pigments (0.04 gg(-1)d(-1)) was favorable in starch medium. P. sinclairii grown in sucrose medium were highly branched and showed longer hyphal lengths than that in starch medium. The consistency index (K) in sucrose medium was markedly higher than that in starch medium due to higher cell mass, while the higher values of flow behavior index (n) were indicated at the late stationary phase in starch medium. The aeration rate was varied within the ranges from 0.5 to 3.5 vvm while running the fermentation at mild agitation of 150 rpm using sucrose as the carbon source. The maximum biomass concentration of P. sinclairii was about 33 gl(-1) with an aeration rate of 1.5 vvm, whereas the maximum yield of red pigment production (4.73 gl(-1)) was achieved with 3.5 vvm. The highly branched cell morphology appeared at 1.5 vvm and the highly vacuolated cell morphology was observed in a high aeration rate (3.5 vvm). There was no significant variance in rheological parameters (K and n) between culture broths from different aeration conditions.     

Rheology of filamentous fermentations

The performance of a bioreactor containing a filamentous fermentation broth is greatly influenced by the rheological properties of the broth. These properties are determined mainly by the concentration of biomass, its growth rate and morphology. Included in the morphology are such factors as the geometry of hyphae (length, diameter, branching frequency), hyphal flexibility and hyphal-hyphal interactions, which can all be affected by the operational design of the reactor. Thus, correlations describing viscosity as a function of biomass only are of limited value. A better understanding of the relations between morphology and rheology may be achieved by a combination of rheological and morphological studies.Rheological properties are normally determined using off-line measurements in-spite of associated problems with sample treatment influencing the results. Equipment for dynamic, on-line, measurement of morphology and rheology is available, but little used in filamentous fermentations. Controlling the rheological properties of mycelial fermentations may be difficult because of the great number of factors influencing mycelial development and/or hyphal-hyphal interactions.Polymer solutions are often used to simulate flow behaviour of filamentous fermentations and scale-up and mass transfer considerations are based on these studies. Although much information has been gained this way, the predictions developed do not include the effect of an active biomass on the mass transfer and flow properties of the culture. It is important to carry out studies on the non-homogeneous fermentation fluids, and develop correlations based on these studies.     

Relationship between morphology,rheology and polygalacturonase production by Aspergillus sojae ATCC 20235 in submerged cultures

A full factorial statistical design, with the factors of, two taxonomically different strains, seven types of seed culture formulations (slants) and two types of fermentation media were used to investigate the effect of these parameters on the morphology and polygalacturonase production. The rheology of the final fermentation medium was analyzed and appropriate mathematical model was applied to calculate suspension viscosity. It was found that most fermentation broths showed non-Newtonian flow behavior. According to statistical analysis, factors of strain types and fermentation media and the interaction between them were found significant on the enzyme activity. The effect of seed culture formulations (slants) were found insignificant at the significance level of 1%. Interaction of slants with strain types and fermentation media were also found insignificant. Considering the morphology of the final culture, Aspergillus sojae with the desired pellet morphology in a complex media, inoculated with a seed culture prepared from molasses resulted in maximum polygalacturonase enzyme activity (0.2 U/ml) and lowest suspension viscosity with a broth rheology close to Newtonian flow behavior.     

Rheologies and morphologies of three actinomycetes in submerged culture

The broth rheologies and morphologies of three actinomycetes (Saccharopolyspora erythraea, Actinomadura roseorufa, and Streptomyces rimosus) in submerged culture have been examined. The rheology of all the broths became pseudoplastic as soon as significant growth occurred with the power law index, n, falling to 0.20 to 0.25. The consistency index, K, rose with biomass concentration although in some instances it fell later in the fermentation. The mean main hyphal lengths of all cultures were in the range, 15 to 25 mum, and did not alter greatly even when large changes in K were occurring. (c) 1995 John Wiley & Sons, Inc.     

A fractal model for the characterization of mycelial morphology

A new technique based on a fractal model has been developed for the quantification of the macroscopic morophology of mycelia. The morphological structuring is treated as a fractal object, and the fractal dimension, determined by an ultrasonic scattering procedure developed for the purpose, serves as a quantitative morphological index. Experimental observations reported earlier and simulations of mycelial growth, carried out using a probabilistic-geometric growth model developed for the purpose, both validate the applicability of the fractal model. In experiments with three different species, the fractal dimensions of pelletous structures were found to be in the range 1.45-2.0 and those of filamentous structures were in the range 1.9-2.7, with values around 2.0 representing mixed morphologies. Fractal dimensions calculated from simulated mycelia are in rough agreement with these ranges. The fractal dimension is also found to be relatively insensitive to the biomass concentration, as seen by dilution of the original broths. The relation between morphology and filtration properties of the broths has also been studied. The fractal dimension shows a strong correlation with the index of cake compressibility and with the Kozeny constant, two filtration parameters that are known to be morphology dependent. This technique could thus be used to develop correlations between the morphology, represented by the fractal dimension, and important morphology-dependent process variables. (c) 1993 John Wiley & Sons, Inc.     

Morphological characterization of filamentous microorganisms in submerged cultures by on-line digital image analysis and pattern recognition

The morphology of filamentous microorganisms in submerged culture is of great interest. On the one hand, morphology influences rheology and mass transfer in the fermentation broth. On the other hand, morphology could be a visible expression of physiology and metabolism of the microorganisms. An algorithm for the morphological characterization and the estimation of biomass of filamentous microorganisms by means of digital image analysis has been developed. After measurement of eight features the objects in the broth are classified into different morphological classes, i.e., pellet aggregates, rough pellets, smooth pellets, mycelial flocks, and medium components. The classification is based on the measured object parameters and a knowledge base, which was generated in a preceding training phase. The method was tested on Streptomyces tendae Tü 901/8c. A typical batch fermentation in a defined medium is presented. It could be shown that both morphology and physiology have been changed in the course of the fermentation, especially during the transition from trophophase to idiophase. In order to supervise the fermentation processes continuously, an on-line image analysis system has been developed. Sampling, dilution, and image acquisition of the culture were performed under the control of a personal computer. (c) 1997 John Wiley & Sons, Inc.     

Dilution rate as a determinant of mycelial morphology in continuous culture

The morphology of mycelial fungi in liquid culture effects culture rheology and this in turn may affect product yield. It is therefore important to understand how environmental factors influence mycelial morphology and this paper describes the effect of dilution rate on two strains of Fusarium graminearum, the relatively sparsely branched parental strain (A3/5) and a relatively highly branched "colonial" variant (C106). At any given dilution rate, the concentration of mycelial fragments present at steady state of both strains remained approximately constant with time, suggesting that mycelial fragmentation occurred in a regular manner. However, for both strains fragment concentration decreased with increasing dilution rate. The strains had a similar morphology at a dilution rate of 0.07 h(-1). The length of the hyphal growth unit of A3/5 increased with increase in dilution rate, while that of C106 decreased with increase in dilution rate. At all dilution rates, C106 produced up to ten times more macroconidia than A3/5.     

Dependence of mycelial morphology on impeller type and agitation intensity

The influence of the agitation conditions on the morphology of Penicillium chrysogenum (freely dispersed and aggregated forms) was examined using radial (Rushton turbines and paddles), axial (pitched blades, propeller, and Prochem Maxflow T), and counterflow impellers (Intermig). Culture broth was taken from a continuous fermentation at steady state and was agitated for 30 min in an ungassed vessel of 1.4-L working volume. The power inputs per unit volume of liquid in the tank, P/V(L), ranged from 0.6 to 6 kW/m(3). Image analysis was used to measure mycelial morphology. To characterize the intensity of the damage caused by different impellers, the mean total hyphal length (freely dispersed form) and the mean projected area (all dispersed types, i.e., also including aggregates) were used. [In this study, breakage of aggregates was taken into account quantitatively for the first time.]At 1.4-L scale and a given P/V(L), changes in the morphology depended significantly on the impeller geometry. However, the morphological data (obtained with different geometries and various P/V(L)) could be correlated on the basis of equal tip speed and two other, less simple, mixing parameters. One is based on the specific energy dissipation rate in the impeller region, which is simply related to P/V(L) and particular impeller geometrical parameters. The other which is developed in this study is based on a combination of the specific energy dissipation rate in the impeller swept volume and the frequency of mycelial circulation through that volume. For convenience, the function arising from this concept is called the "energy dissipation/circulation" function.To test the broader validity of these correlations, scale-up experiments were carried out in mixing tanks of 1.4, 20, and 180 L using a Rushton turbine and broth from a fed-batch fermentation. The energy dissipation/circulation function was a reasonable correlating parameter for hyphal damage over this range of scales, whereas tip speed, P/V(L), and specific energy dissipation rate in the impeller region were poor. Two forms of the energy dissipation/circulation function were considered, one of which additionally allowed for the numbers of vortices behind the blades of each impeller type. Although both forms were successful at correlating the data for the standard impeller designs considered here, there was preliminary evidence that allowing for the vortices would be valuable. (c) 1996 John Wiley & Sons, Inc.     

Rheology,oxygen transfer,and molecular weight characteristics of poly(glutamic acid) fermentation by Bacillus subtilis

Poly(glutamic acid) (PGA) is a water-soluble, biodegradable biopolymer that is produced by microbial fermentation. Recent research has shown that PGA can be used in drug delivery applications for the controlled release of paclitaxel (Taxol) in cancer treatment. A fundamental understanding of the key fermentation parameters is necessary to optimize the production and molecular weight characteristics of poly(glutamic acid) by Bacillus subtilis for paclitaxel and other applications of pharmaceuticals for controlled release. Because of its high molecular weight, PGA fermentation broths exhibit non-Newtonian rheology. In this article we present experimental results on the batch fermentation kinetics of PGA production, mass transfer of oxygen, specific oxygen uptake rate, broth rheology, and molecular weight characterization of the PGA biopolymer.     

丝状真菌形态控制及其在发酵过程优化中的应用

丝状真菌广泛用于发酵产业,在液体深层发酵过程中,其生长形态与产物种类及产量间存在重要关联,成为发酵过程调控的热点。采用数学模型解释丝状真菌的形态发育与调控机制,是近年来工程学界颇为关注的研究手段。本文结合自己的工作着重解释丝状真菌各种生长形态的生长机理及形态发育的数学描述方式,以及如何采用数学模型描述丝状真菌发酵过程中产物、形态及环境的关联,最终实现形态的控制,完成生物发酵过程优化。具体包括:1)丝状真菌的生长机制;2)形态发育数学模型在发酵过程优化中的应用;3)控制丝状真菌形态的策略。     

A simple model for the optimization of the extraction yield of antibiotics isolated from fermented broths by direct crystallization

This article is concerned with the development of a model to maximize the overall yield of isolation of antibiotics recovered from fermented broths by the so-called direct precipitation method. In this process, as in most antibiotics isolation processes, a second filtration of the semiexhaust mycellium from the first filtration, after slurrying it in water at the suitable pH, is required. The maximization of the overall yield of isolation implies the use of an optimal amount of water, measured as a volume to fermented broth mass ratio, which can be calculated by using the model derived here. The model also allows for the calculation of the partial and overall yields of the isolation process, and its validity is demonstrated by its ability to describe reasonably well the isolation data of two different tetracycline-fermented broths produced according to two different technologies.The application of the model requires only the knowledge of easily obtainable fermented broth parameters and is illustrated for two different types of tetracycline-fermented broths. Although the model had been derived for the optimization of the overall yield of isolation of antibiotics recovered by direct precipitation, it can easily be adapted to be used for the optimization of the overall yield of isolation of antibiotics recovered by other isolation processes. (c) 1993 John Wiley & Sons, Inc.     

Effect of the degree of dilution of the antibiotic fermentation broths on the filtration indices]

Dilution of the fermentation broths with water before the mycelium separation lowered the specific cake resistance. The effect of the dilution on the filtration duration was different and depended on the fermentation broth type. As for the erythromycin fermentation broth, the time of its filtration decreased after the dilution, while the filtration time of the fermentation broths of the other 2 antibiotic-producing organisms increased after the dilution.     

Flocculation of Aspergillus terreus with polyelectrolyte complex and production of itaconic acid with the flocculated mycelia

Mycelia from Aspergillus terreus K 26 were flocculated with a polyelectrolyte complex consisting of potassium poly9vinyl alcohol) sulfate (KPVS) and poly(diallyldimethyl-ammonium chloride) (PDDA) by three different methods: (a) PDDA was added into the broth obtained from precultivation of the hyphal inoculum in the presence of KPVS; (b) use of KPVS and PDDA was reversed from that in method a; (c) after the precultivation in the absence of the polymer, the mycelia were harvested, dispersed in 0.1 M phosphate buffer containing PDDA, then flocculated by addition of KPVS. The three types of the flocculated mycelia were investigated concerning growth and itaconic acid production in shake flask cultures. Viscosity and sedimentation were further examined to characterize the flocculated mycelial broths. A slight inhibition caused by flocculation on growth and acid production was observed at the beginning of repeated cultivation, but this was eliminated when cultivation in the fresh medium was repeated. There was no marked difference in the specific rates of acid production between fre and flocculated cells. Viscosity of the flocculated mycelial system was close to that of the medium, even while maintaining a cell concentration of 2 g/dl. The poor sedimentation of mycelia was favorably imporved with these flocculation methods, especially with methods b and c.     

Identification of Armillaria field isolates using isozymes and mycelial growth characteristics

This research was conducted to develop procedures based on mycelial growth characteristics and patterns of esterase (EST) and polyphenol oxidase (PPO) production by diffuse mycelia for identification of Armillaria field isolates from Quercus-Carya-Pinus forests in the Ozark Mountains (central USA). The 285 isolates collected were first identified by standard diploid-haploid pairing tests as A. gallica, A. mellea, or A. tabescens. A strong PPO band was diagnostic for A. gallica. All A. mellea isolates tested and 91% of the A. tabescens isolates tested were distinguished based on production of EST bands in three standardized R f ranges. A procedure based on mycelial growth and morphology on tannic acid medium (TA) at 24 °C and on malt extract medium (ME) at 33 °C correctly identified 98% of A. gallica isolates and all A. mellea and A. tabescens isolates. On TA, A. gallica grew slowest. On ME, A. mellea grew slowest: mycelial morphology differed among species; A. gallica typically stained the agar and produced an appressed/submerged growth pattern with concentric bands of decreasing hyphal density, A. mellea typically did not stain the agar and produced round mycelia with smooth margins and abundant aerial hyphae, A. tabescens typically stained the agar and grew appressed/submerged with very irregular margins and patchy hyphal density. These are the first published systems evaluating the potential for identifying Armillaria field isolates based on their mycelial growth characteristics and EST and PPO complements. This revised version was published online in June 2006 with corrections to the Cover Date.     

Improved performance in viscous mycelial fermentations by agitator retrofitting

For viscous mycelial fermentations it was demonstrated at the pilot-plant scale that the replacement of standard radial flow Rushton turbines with larger diameter axial-flow Prochem hydrofoil impellers significantly improved oxygen transfer efficiency. It was also determined that the Streptomyces broth under evaluation is highly shear thinning. Separate experiments using a Norcardia broth with similar Theological properties demonstrated that the oxygen transfer coefficient, K(L)a, can be greatly increased by use of water additions to reduce broth viscosity. These observations are consistent with the hypothesis that the improvement in oxygen transfer by changing agitator types is primarily due to an improvement in bulk mixing. A model is presented, based on the concepts of Bajpai and Reuss, which explains this improvement in performance in terms of enlargement of the well mixed micromixer region for viscous mycelial broths.     

Effect of deletion of chitin synthase genes on mycelial morphology and culture viscosity in Aspergillus oryzae

The objective of this study was to quantify the effect of disrupting two chitin synthases, chsB and csmA, on the morphology and rheology during batch cultivation of Aspergillus oryzae. The rheological properties were characterized in batch cultivations at different biomass concentrations (from 3.4-22.5 g kg(-1) biomass) and the power-law model adequately described the rheological properties. In the cultivations there were pellets, clumps, and freely dispersed hyphal elements. The different morphological fractions were quantified using image analysis. The apparent viscosity of the fermentation broth was significantly affected by the biomass concentration, the morphology, and also by pH. The chsB disruption strain had lower consistency index K values for all biomass concentrations investigated, which is a desirable trait for industrial Aspergillus fermentations.     

Pellet morphology, culture rheology and lovastatin production in cultures of Aspergillus terreus

Pellet growth of Aspergillus terreus ATCC 20542 in submerged batch fermentations in stirred bioreactors was used to examine the effects of agitation (impeller tip speed u(t) of 1.01-2.71 ms(-1)) and aeration regimens (air or an oxygen-enriched mixture containing 80% oxygen and 20% nitrogen by volume) on the fungal pellet morphology, broth rheology and lovastatin production. The agitation speed and aeration methods used did not affect the biomass production profiles, but significantly influenced pellet morphology, broth rheology and the lovastatin titers. Pellets of approximately 1200 microm initial diameter were reduced to a final stable size of approximately 900 microm when the agitation intensity was >/=600 rpm (u(t)>/=2.03 ms(-1)). A stable pellet diameter of approximately 2500 microm could be attained in less intensely agitated cultures. These large fluffy pellets produced high lovastatin titers when aerated with oxygen-enriched gas but not with air. Much smaller pellets obtained under highly agitated conditions did not attain high lovastatin productivity even in an oxygen-enriched atmosphere. This suggests that both an upper limit on agitation intensity and a high level of dissolved oxygen are essential for attaining high titers of lovastatin. Pellet size in the bioreactor correlated equally well with the specific energy dissipation rate and the energy dissipation circulation function. The latter took into account the frequency of passage of the pellets through the high shear regions of the impellers. Pellets that gave high lovastatin titers produced highly shear thinning cultivation broths.     

A new sensor,the “filtration probe,” for quantitative characterization of the penicillin fermentation. II. The monitor of mycelial growth

Biomass concentration during penicillin production can be estimated rapidly and with reasonable accuracy using the “filtration probe.” The basis for the measurement is the volume of the filter cake which, in contrast to the conventional “packed-cell volume” measured by centrifugation, is only moderately affected by the morphology of the mycelia. The influence of the mycelial morphology on the specific filter cake volume [ υ (cm³ cake/g dry cells)] can additionally, to a large extent, be predicted from the (specific) filtration resistance of the broth. During the rapid (exponential) growth period, the specific cake volume is, however, more variable and typically exhibits a transient maximum value. The presence of such a maximum can be explained by a simple model for exponential growth of single mycelial particles. this model is based upon conventional kinetics for hyphae elongation and branching and applies well to experimental data (filtration behavior as well as microscopic studies) provided hyphae fragmentation is negligible (i.e., at high growth rates, μ ? μ_max).