Scaling-up vaccine production: implementation aspects of a biomass growth observer and controller

This study considers two aspects of the implementation of a biomass growth observer and specific growth rate controller in scale-up from small- to pilot-scale bioreactors towards a feasible bulk production process for whole-cell vaccine against whooping cough. The first is the calculation of the oxygen uptake rate, the starting point for online monitoring and control of biomass growth, taking into account the dynamics in the gas-phase. Mixing effects and delays are caused by amongst others the headspace and tubing to the analyzer. These gas phase dynamics are modelled using knowledge of the system in order to reconstruct oxygen consumption. The second aspect is to evaluate performance of the monitoring and control system with the required modifications of the oxygen consumption calculation on pilot-scale. In pilot-scale fed-batch cultivation good monitoring and control performance is obtained enabling a doubled concentration of bulk vaccine compared to standard batch production.     

Adaptation of the "Dynamic Method" for measuring the specific respiration rate in oxygen transfer systems through diffusion membrane

Monitoring the specific respiration rate (Q(O2)) is a valuable tool to evaluate cell growth and physiology. However, for low Q(O2) values the accuracy may depend on the measurement methodology, as it is the case in animal cell culture. The widely used "Dynamic Method" imposes serious difficulties concerning oxygen transfer cancellation, especially through membrane oxygenation. This paper presents an improved procedure to this method, through an automated control of the gas inlet composition that can minimize the residual oxygen transfer driving force during the Q(O2) measurement phase. The improved technique was applied to animal cell cultivation, particularly three recombinant S2 (Drosophila melanogaster) insect cell lines grown in a membrane aeration bioreactor. The average measurements of the proposed method reached 98% of stationary liquid phase balance method, taken as a reference, compared to 21% when the traditional method was used. Furthermore, this methodology does not require knowledge of the volumetric transfer coefficient k(L)a, which may vary during growth.     

Investigation of the use of agricultural byproducts for fungal protein production

Cellulose and nutrient salts as well as potato pulp and potato protein liquor (PPL), were used as substrates for the cultivation of Chaetomium cellulolyticum in batch and repeated-batch operations. Using cellulose as the substrate a linear relationship existed between the rates of cell mass formation and acid production. The repeated-batch process was controlled by NaOH consumption using a simple computer model. When the production of cell mass and acid stopped because of a lack of substrate cellulose was fed into the reactor. This occurred within 10 min at which point no NaOH-feed was needed to maintain a constant pH. Repeated-batch operations yielded higher cell concentrations and productivities than batch operations. The relationship between the NaOH and H₂SO₄ consumed, and the fungal mass concentration was complex in cultivation media containing potato pulp and PPL, because various substrates were consumed by the fungus simultaneously and successively. Therefore, for repeated-batch cultivation a constant time interval was used. Repeated-batch cultivation of the fungus on potato pulp and PPL did not yield higher cell concentrations and productivities than did batch cultivation. With the optimal pulp-to-PPL ratio a maximum specific growth rate of 0.61 h¹ was obtained. These investigations indicate, that potato pulp and PPL are well suited to fungal protein production by Chaetomium cellulolyticum for fodder supplement.     

五种典型藻类对C，N，P吸收动力学分析及种间竞争模拟

目的:获得五种典型藻类(甲藻属微小亚历山大藻(Alexandrium minutum)和锥状斯氏藻(Scrippsiella trochoidea),赤潮硅藻中肋骨条藻(Skeletonema costatum)以及绿藻属杜氏藻(Dunaliella salina)和青岛大扁藻(Platymonas helgolandica tsingtaoensis))对C,N,P营养的吸收动力学参数,并利用经典藻类种间竞争模型,构建一个藻类混合共存的生态平衡体系,揭示藻类种间竞争规律,为赤潮爆发机制和预测的研究提供一个新思路。方法:监测批次培养过程中藻体的生长规律以及培养基中C,N,P营养的消耗,计算出藻类营养吸收动力学参数,将参数代入Huisman-Weissing竞争模型,模拟藻类种间竞争。结果:(1)在单独培养条件下,杜氏藻具有最高的比生长率(0.834 d~(-1))和最大细胞浓度(3.4×10~6 cells/mL),锥状斯氏藻和微小亚历山大藻的比生长率μ和最大细胞浓度与其它三种藻相比均明显偏低,p0.01;(2)随着环境总碳浓度从5 mM提高到20 mM,五种藻的比生长率和最大细胞浓度均显著上升,其中杜氏藻和青岛大扁藻对C浓度改变的响应更加敏感;(3)杜氏藻和中肋骨条藻理论最大比生长率(μmax)明显高于其它三种藻类,锥状斯氏藻和微小亚历山大藻对C,N,P营养盐的需求量相比于其它三种藻明显偏高,p0.01;(4)藻类共生平衡系统中,N营养添加有利于杜氏藻和中肋骨条藻发挥更好的种间竞争优势,P营养添加有利于微小亚历山大藻和锥状斯氏藻发挥种间竞争优势;结论:不同环境条件下,五种藻类最大比生长速率μmax和营养吸收半饱和常数Ks直接影响它们的种间竞争能力,基于藻类动力学参数的种间竞争模型为赤潮爆发机制和预测的研究提供一个新思路。     

Online automatic tuning and control for fed-batch cultivation

Performance of controllers applied in biotechnological production is often below expectation. Online automatic tuning has the capability to improve control performance by adjusting control parameters. This work presents automatic tuning approaches for model reference specific growth rate control during fed-batch cultivation. The approaches are direct methods that use the error between observed specific growth rate and its set point; systematic perturbations of the cultivation are not necessary. Two automatic tuning methods proved to be efficient, in which the adaptation rate is based on a combination of the error, squared error and integral error. These methods are relatively simple and robust against disturbances, parameter uncertainties, and initialization errors. Application of the specific growth rate controller yields a stable system. The controller and automatic tuning methods are qualified by simulations and laboratory experiments with Bordetella pertussis.     

多鳞四须鲃耗氧率、排氨率和窒息点的初步研究

控制水温在(20±0.5)℃条件下,采用Winkler法和奈氏试剂法分别测定水中的溶氧含量和氨氮含量,通过比较流水呼吸室进、出口水中的溶解氧和氨氮含量之差以确定多鳞四须鲃(Barbodes schwanenfeldi)的耗氧率、排氨率及窒息点.结果表明,多鳞四须鲃耗氧率随体重增加而减小,关系式为Y=0.24X^-0.09(R²=0.9028);随放养密度的增大而减小,关系式为Y=-0.029X+0.3301 (R²=0.9291).排氨率随体重的增加而减小,关系式为Y=-0.0008X+0.2433 (R²=0.9817);随放养密度的增大而增加,关系式为Y=-0.050X+0.4979 (R²=0.9889).多鳞四须隹巴晚间(18:00～4:00)的耗氧率明显高于白天(6:00-1:00),排氨率则相反,白天的排氨率相对较高,表明多鳞四须鲃巴属于"昼伏夜出"型鱼类.多鳞四须啬巴的窒息点为1.2572mg·L^-1,耐氧性较差.     

Modeling and optimization of alpha-amylase production in a recombinant yeast fed-batch culture taking account of the cell cycle population distribution.

A simple mathematical model describing the cell cycle dependency of rice alpha-amylase production by a recombinant yeast was constructed to investigate the efficiency of cell cycle population control. First, the effects of the glucose concentration and cultivation temperature on the specific growth rate, the specific production rate of rice alpha-amylase, and the distribution of the cell cycle population were studied under balanced growth conditions. On the basis of the results, parameter values for the mathematical model were then estimated. The proposed model was shown to be applicable for unbalanced as well as balanced growth phases. The optimal control strategy in respect of temperature and glucose concentration for maximum rice alpha-amylase production, taking into account the cell cycle population, was determined and the result was compared with that obtained by a simple mathematical model in which cell cycle distribution was not considered. Finally, the effect of the initial population of each cell cycle phase on the final amount of the product under optimal operational conditions was investigated. The simulation and experimental data coincided well with each other, and the model was used to optimize the control strategy for maximum alpha-amylase production.     

Mitochondrial hydrogen peroxide production alters oxygen consumption in an oxygen-concentration-dependent manner

Metabolic responses of mammalian cells toward declining oxygen concentration are generally thought to occur when oxygen limits mitochondrial ATP production. However, at oxygen concentrations markedly above those limiting to mitochondria, several mammalian cell types display reduced rates of oxygen consumption without energy stress or compensatory increases in glycolytic ATP production. We used mammalian Jurkat T cells as a model system to identify mechanisms responsible for these changes in metabolic rate. Oxygen consumption was 31% greater at high oxygen (150–200 μM) compared to low oxygen (5–10 μM). Hydrogen peroxide was implicated in the response as catalase prevented the increase in oxygen consumption normally associated with high oxygen. Cell-derived hydrogen peroxide, predominately from the mitochondria, was elevated with high oxygen. Oxygen consumption related to intracellular calcium turnover was shown, through EDTA chelation and dantrolene antagonism of the ryanodine receptor, to account for 70% of the response. Oligomycin inhibition of oxygen consumption indicated that mitochondrial proton leak was also sensitive to changes in oxygen concentration. Our results point toward a mechanism in which changes in oxygen concentration influence the rate of hydrogen peroxide production by mitochondria, which, in turn, alters cellular ATP use associated with intracellular calcium turnover and energy wastage through mitochondrial proton leak.     

Optimal production of curdlan by Agrobacterium sp. with feedback inferential control of optimal pH profile

The pH control was important for curdlan production with Agrobacterium sp. ATCC31750. Specific cell growth rate was the highest at pH 7 and the specific curdlan production rate was at pH 5.5. The pH profiles maximizing curdlan production was changed from pH 7 optimal for cell growth to pH 5.5 optimal for curdlan production after ammonium consumption. The feedback inferential control methods, with easily measurable variables such as NaOH addition for pH control and dissolved oxygen (DO), were also applied. The pH was successfully controlled to follow optimal profiles and the maximal production of curdlan (60 g l^–1 in 120 h) was achieved with feedback optimal control.     

Effects of cell density and temperature on oxygen consumption rate for different mammalian cell lines.

Oxygen consumption rates were measured in a respirometer for different mammalian cell lines (BHK, murine hybridoma, and CHO), and the effects of cell density (1-20 million cells/mL) and temperature (6 to 37 degrees C) on specific oxygen consumption rate were investigated. The specific oxygen consumption was cell line dependent. For a given temperature, the murine hybridoma cells had the lowest and the CHO cells had the highest oxygen consumption rate. The specific oxygen consumption rate was not affected by the cell concentration for cell densities between 1 and 20 million cells/mL. However, artificial trends implicating the effects of cell density were obtained when traditional analysis was used and the probe response time was neglected. A detailed mathematical analysis was presented to investigate the magnitude of errors originating from neglecting the probe response time for the calculation of oxygen consumption rate. The error was significant, especially when the probe response was slow and/or the oxygen consumption was fast. Temperature influenced the specific oxygen consumption rate similarly for the cells studied, and about 10% decrease was observed in specific oxygen consumption by 1 degrees C decrease in the temperature. Between 6 and 37 degrees C, the effect of temperature on oxygen consumption rate could be described using an Arrhenius model, i.e., qO2 = qoO2. e-E/RT. The activation energy, E, in this equation was similar for different cells (between 80 and 90 kJ/mol), indicating the action of a similar mechanism for the effect of temperature on oxygen consumption.     

Control of carbon source supply and dissolved oxygen by use of carbon dioxide concentration of exhaust gas in fed-batch culture

Accurate and automatic control strategies for a feedback-control system of volatile carbon source feeding and dissolved oxygen (DO) level were investigated. To maintain the optimal ethanol concentration for microbial growth, carbon dioxide concentration in exhaust gas was used as a stepwise control parameter of ethanol feeding. A proportional-differential (PD) control program was used to correct the errors. The coefficient of stepwise control was calculated stoichiometrically, and parameters of PD were experimentally preset and were not changed during cultivation. DO was also controlled by the PD control and the stepwise program based on carbon dioxide concentration of the exhaust gas. Agitation speed and partial pressure of oxygen of the inlet gas were changed stepwise in accordance with the oxygen consumption rate. The stepwise coefficients were estimated from stoichiometry and material balance of molecular oxygen. The PD control program was only used for the agitation speed control to correct the fluctuations of DO level. The parameters did not need to be changed during cultivation. By use of these sophisticated control programs for fed-batch culture of Candida brassicae, ethanol concentration and DO level were accurately controlled at 3.4–3.7 g/l and 2.2–2.8 ppm, respectively, while cell mass concentration reached about 80 g/l. No manual operation was needed.     

Functional expression of human pyruvate carboxylase for reduced lactic acid formation of Chinese hamster ovary cells (DG44)

To investigate the effect of human pyruvate carboxylase (hPC) on lactate formation in Chinese hamster ovary (CHO) cell lines, FLAG-tagged hPC was introduced into a dihydrofolate-deficient CHO cell line (DG44). Three clones expressing high levels of hPC, determined by Western blotting using an anti-FLAG monoclonal antibody, and a control cell line were established. Immunocytochemistry revealed that a substantial amount of expressed hPC protein was localized in the mitochondria of the cells. hPC expression did not impair cell proliferation. Rather, it improved cell viability at the end of adherent batch cultures with the serum-containing medium probably because of reduced lactate formation. Compared with control cells, specific lactate production rate of the three clones was decreased by 21–39%, which was because of a decreased specific glucose uptake rate and yield of lactate from glucose. Reduced lactate formation by hPC expression was also observed in suspension fed-batch cultures using a serum-free medium. Taken together, these results demonstrate that through the expression of the hPC enzyme, lactate formation in CHO cell culture can be efficiently reduced.     

Improvement of hEGF production with enhanced cell division ability using dissolved oxygen responses to pulse addition of tryptone

Tryptone has multiple and complex effects on cell physiology and process performance in pulse fed-batch cultivation of recombinant Escherichia coli. By applying feedback control of dissolved oxygen signal responding to pulse in the feed rate, the production of acetate was avoided and the optimization of production of recombinant human epidermal growth factor (hEGF) was successfully achieved. With the addition of an optimum amount of tryptone along with glucose in the pulse fedbatch cultivation of E. coli, the ability of the cell to divide and the stability of the plasmid within the bacteria were improved. Consequently, segregation of the cells into a viable but non-culturable physiological state was alleviated. Addition of tryptone also enhanced cell respiration before and after hEGF expression and thus further benefited the production of recombinant hEGF. Excessive addition of tryptone resulted in low sensitivity of the oscillation of dissolved oxygen signal and poor operability of pulse fed-batch cultivation as this led to an accumulation of acetate, which weakened the dissolved oxygen signal responses. Consequently, the production of recombinant protein was considerably reduced. By combining the process performance and the positive effect of complex media pulse addition on bacterial metabolism, the optimal production conditions of hEGF were successfully determined. A high cell density of 91 g/L dry cell weight was obtained under these optimal production conditions. Furthermore, a high level of 0.24 g/L hEGF was attained leading to a 32.6% increase in product yield as compared to the controls.     

Use of fed-batch cultivation for achieving high cell densities for the pilot-scale production of a recombinant protein (phenylalanine dehydrogenase) in Escherichia coli

A fed-batch process for the high cell density cultivation of E. coli TG1 and the production of the recombinant protein phenylalanine dehydrogenase (PheDH) was developed. A model based on Monod kinetics with overflow metabolism and incorporating acetate utilization kinetics was used to generate simulations that describe cell growth, acetate production and reconsumption, and glucose consumption during fed-batch cultivation. Using these simulations a predetermined feeding profile was elaborated that would maintain carbon-limited growth at a growth rate below the critical growth rate for acetate formation (mu < mu(crit)). Two starvation periods are incorporated into the feed profile in order to induce acetate utilization. Cell concentrations of 53 g dry cell weight (DCW)/L were obtained with a final intracellular product concentration of recombinant protein corresponding to approximately 38% of the total cell protein. The yield of PheDH was 129 U/mL with a specific activity of 1.2 U/mg DCW and a maximum product formation rate of 0.41 U/mg DCW x h. The concentration of aectate was maintained below growth inhibitory levels until 3 h before the end of the fermentation when the concentration reached a maximum of 10.7 g/L due to IPTG induction of the recombinant protein.     

Model-based optimization of viral capsid protein production in fed-batch culture of recombinant <Emphasis Type="Italic">Escherichia coli</Emphasis>

An optimized fed-batch cultivation process for the production of the polyoma virus capsid protein VP1 in recombinant Escherichia coli BL21 bacteria is presented. The optimization procedure maximizing the amount of desired protein is based on a mathematical model. The model distinguishes an initial cell growth phase from a protein production phase initiated by inducer injection. A new approach to model the target protein formation rate was elaborated, where product formation is primarily dependent on the specific biomass growth rate. Lower growth rates led to higher specific protein concentrations. The model was identified from a series of fed-batch experiments designed for parameter identification purposes and possesses good prediction quality. Then the model was used to determine optimal open-loop control profiles by manipulating the substrate feed rates in both phases as well as the induction time. Feed-rate optimization has been solved using Pontryagin's maximum principle. The solution was validated experimentally. A significant improvement of the process performance index was achieved.     

不同功率的激光刺激对小鼠C2C12成肌细胞耗氧率水平的影响及机制

目的：探讨不同功率的低强度650 nm激光刺激对C₂C₁₂成肌细胞耗氧率水平和相关蛋白的影响及其机制。方法：以体外培养的C₂C₁₂小鼠成肌细胞作为实验对象,以4×10⁵个/孔接种于牵张6孔板中,采用输出功率5 mW,波长650 nm的二极管激光进行单次刺激,激光照射剂量分别0 J/cm²（0 min）、0.4 J/cm²（12.8 min）、0.8 J/cm²（25.6 min）。实验结束后,采用耗氧率试剂盒（Luxcel Biosciences）检测细胞耗氧率;提取细胞总蛋白,采用Western blot技术检测成肌调节因子（MyoD）、过氧化物酶体增殖活化受体γ共激活因子1α（PGC-1α）、雷帕霉素靶蛋白和磷酸化蛋白（p-mTOR/mTOR）表达。结果：与对照组相比,低剂量组细胞氧化耗氧率结果、MyoD、PGC-1α蛋白表达显著增加（P<0.05）,高剂量组MyoD、PGC-1α蛋白表达显著增加（P<0.05）,p-mTOR/mTOR蛋白显著降低（P<0.05）。结论：较低剂量（0.4 J/cm²）的650 nm低强度激光增强了细胞氧化功能水平,并对细胞分化相关蛋白有一定影响。其机制可能与适宜的激光刺激影响PGC-1α蛋白的表达,进而影响线粒体氧化呼吸有关。     

Enhancement of glucose oxidase production in batch cultivation of recombinant Saccharomyces cerevisiae: optimization of oxygen transfer condition

AIMS: To obtain an optimal combination of agitation speed and aeration rate for maximization of specific glucose oxidase (GOD) production in recombinant Saccharomyces cerevisiae, and to establish a correlation between kLa vis-à-vis oxygen transfer condition and specific glucose oxidase production. METHODS AND RESULTS: The oxygen transfer condition was manifested indirectly by manipulating the impeller speed and aeration rate in accordance with a Central Composite Rotatory Design (CCRD). The dissolved oxygen concentration and the volumetric oxygen transfer coefficient (kLa) were determined at corresponding combinations of impeller speed and aeration rate. The maximal specific extracellular glucose oxidase production (3.17 U mg-1 dry cell mass) was achieved when the initial dissolved oxygen concentration was 6.83 mg l-1 at the impeller speed of 420 rev min-1 and at the rate of aeration of 0.25 vvm. It was found out that while impeller speed had a direct effect on the production of enzyme, a correlation between kLa and specific GOD production could not be established. CONCLUSION: At the agitation speed of 420 rev min-1 and at 0.25 vvm aeration rate, the degree of turbulence and the dissolved oxygen concentration were thought to be optimal both for cellular growth and production of enzyme. SIGNIFICANCE AND IMPACT OF THE STUDY: The combined effect of agitation and aeration on recombinant glucose oxidase production in batch cultivation has not yet been reported in the literature. Therefore, this study gives an insight into the effect of these two important physical parameters on recombinant protein production. It also suggests that since there is no correlation between kLa and specific production of GOD, kLa should not be used as one of the scale-up parameters.     

Method for determining oxygen consumption rates of static cultures from microplate measurements of pericellular dissolved oxygen concentration

We describe a simple protocol for determining the oxygen consumption of cells in static culture. The protocol is based on a noninvasive oxygen-sensing microplate and a simple mathematical model derived from Fick's Law. The applicability of the model is confirmed by showing the correlation of computed oxygen consumption rate (OCR) values to actual cell densities ascertained by direct cell counting and/or MTT for HL60 and U937 cells cultured in suspension. Correlation between computed OCR and these other indications of cell number was quite good, as long as the cultures were not diffusion-limited for oxygen. The impact of the geometric factors of media depth and well size were confirmed to be consistent with the model. Based on this demonstrated correlation, we also developed a simple, completely noninvasive algorithm for ascertaining the per-cell oxygen utilization rate (OUR), which is the ratio of OCR to cell number, and a fundamental cell characteristic. This is accomplished by correlating the known seed densities to extrapolated determinations of OCR at time zero. Such determinations were performed for numerous cell types, in varying well sizes. Resulting OUR values are consistent with literature values acquired by far more painstaking methods, and ranged from <0.01 fmol.min(-1).cell(-1) for bacteria to 0.1-10 fmol.min(-1).cell(-1) for immortalized mammalian and insect cell lines to >10 fmol.min(-1).cell(-1) for primary hepatocytes. This protocol for determining OCR and OUR is extremely simple and broadly applicable and can afford rapid, informative, and noninvasive insight into the state of the culture.     

A new culture system for the cultivation of mammalian cells for the production of several biologically active substances

A maximum cell density of 8×10⁶ viable human fibroblast cells/ml was obtained on microcarriers at a perfusion rate of 0.6 mL/min — a rate which maintained a quasi-steady state. The maximum tPA production was approximately 1.2 g/ml and obtained when the cell density was relatively constant during the later periods of cultivation. Specific UTP and tPA production rates had a correlation factor of 0.85, and cell growth to oxygen consumption had an 0.92 correlation factor. ATP generation was strongly correlated to glutamine consumption, with a lower correlation to oxygen utilization.