Windows of operation for bioreactor design for the controlled formation of tissue‐engineered arteries

The availability of large numbers of units of artificial arteries would offer significant benefits to the clinical management of bypass surgery. Tissue engineering offers the potential of providing vessels that can mimic the morphology, function, and physiological environment of native vessels. Ideally this would involve culturing stem cells in vitro within a biodegradable tubular scaffold so as to construct tissue for implantation. Essential to establishing a robust process for the production of tissue‐engineered arteries is the understanding of the impact of changes in the operating conditions and bioreactor design on the construct formation. In this article, models of transport phenomena were developed to predict the critical flow rates and mass transfer requirements of a prototype bioreactor for the formation of tissue‐engineered arteries. The impact of the cell concentration, tube geometry, oxygen effective diffusivity in alginate, substrate and metabolite concentration levels, feed rate, and recycle rate on the design of the bioreactor was visualized using windows of operation and contour plots. The result of this analysis determined the best configuration of the bioreactor that meets the cellular transport requirements as well as being reliable in performance while seeking to reduce the amount of nutrients to be used. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Periodic operation of immobilized live cell bioreactor for the production of candicidin

A lumped model for cell growth and secondary metabolite production in an immobilized live cell bioreactor has been developed. This model is applied here to simulate the performance of an immobilized bioreactor under steady-state conditions and under conditions of periodically varying concentration of a growth-limiting substrate. The results of the simulation study were experimentally verified in the case of the production of the antibiotic candicidin by Streptomyces griseus in an immobilized bioreactor with forced periodic operation. The results of the studies suggest that periodically operated immobilized live cell bioreactors can provide a potent alternative for the production of non-growth-associated biochemicals, as compared to free cell fermentations, pulsed fermentations with process cycle regeneration, and nonregenerated bioreactors. This work has demonstrated that by frequent pulsing of the growth limiting nutrient, stable extended production can be obtained at high specific cellular productivities.     

Performance of tapered column packed-bed bioreactor for ethanol production

A tapered column type of bioreactor system packed with immobilized Saccharomyces cerevisiae was used to study the bioreactor performance as a function of design and operating variables. The performance of tapered column bioreactor system was found to be better than that of the conventional cylindrical column reactor system for the ethanol fermentation. The new bioreactor design alleviated problems associated with carbon dioxide evolution and provided a significantly better flow pattern for both liquid and gas phases in the bioreactor without local channelling. A mathematical simulation model, which takes into account of the axial convection and dispersion, interphase mass transfer, and apparent kinetic design parameters, was developed. The effect of radial concentration gradients on the bioreactor performance was found to be insignificant. For the reactor system studied, the maximum ethanol productivity obtained was 60 g ethanol/L gel/h, and the maximum glucose assimilation rate was 140 g glucose/L gel/h. One of the most important findings from this study was that the apparent kinetic parameters change at the glucose concentration of 2 g/L This change was found to be due to the changes in yeast physiology and metabolism. The values of V(m) (') and V(m) (') decreased from 0.8 to 0.39 g ethanol/g cell/h and from 97mM to 11mM, respectively. The substrate inhibition constant was estimated as 0.76M and the product inhibition constant was determined as 113 g ethanol/L The degree of product inhibition showed practically a linear relationship with an increasing ethanol concentration. Based on the hydro-dynamic analysis of the bioreactor system, it was found that the Peclet number, N(Pe) was not a strong function of the flow velocity at low flow rates through the bioreactor system, but its value decreased somewhat at an interstitial velocity greater than 0.03 cm/s. The tapered column bioreactor system showed a much better flow pattern of gas and liquid phases within the reactor, thereby providing a more homogeneous distribution of gas-liquid-solid phases in the reactor without any phase separation.     

Dynamic modeling and simulation of continuous airlift bioreactors

For dynamic behaviors of continuous airlift bioreactors, a mathematical model based on a tanks-in-series model with backflow has been developed. The equations describing the dynamics of airlift bioreactors are material balances for micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and heat balances. Non-ideal mixing of liquid and gas phases is taken into account using a tanks-in-series model with backflow. The batch operation, startup operation and the consequence of plant failure were simulated and the effects of design and operating parameters for an airlift bioreactor on its dynamic behaviors were discussed. The concentration profiles of micro-organism, substrate, dissolved oxygen and oxygen in gas-phase and the temperature profile in an airlift bioreactors and their dynamics were obtained. The computational results indicate that the transients of a chemostat in the case of bubble column bioreactor are slower compared with those in the case of airlift bioreactor. The proposed simulator is more precise as compared with models published previously in the literature and therefore provides more reliable and rational examination of continuous airlift bioreactor performance.     

Analysis of a continuous, aerobic, fixed-film bioreactor. II. Dynamic behavior

The dynamic analysis of a continuous, aerobic, fixed-film bioreactor has been performed. Rigorous mathematical models have been developed for a fluidized-bed fermentor with biofilm growth. The transient performance of the reactor is appraised in terms of outlet penicillin concentration for constant, as well as variable carbon substrate feed rates. The effect of the reactor oxygen transfer capacity is elucidated for those cases employing substrate feeding strategies. The results show that penicillin production in a continuous, fixed-film bioreactor reaches a maximum with processing time, but subsequently decreases as cell mass accumulates and substrate deficiencies occur. The maximum production level can be maintained for increased operating times if the substrate supply is continuously increased. The duration of this prolonged production is a direct function of the rate of increase and the operating time at which the increase is initiated. The oxygen transfer capacity of the reactor was found to be important to the effectiveness of a feeding strategy.     

Enzymatic resolution of (S)-(+)-naproxen in a continuous reactor

An enzymatic method for the continuous production of (S)-(+)-2-(6-methoxy-2-naphthyl) propionic acid (Naproxen) has been developed. The process consists of a stereoselective hydrolysis of the racemic Naproxen ethoxyethyl ester catalyzed by Candida cylindracea lipase. The reaction has been carried out in a continuous-flow closed-loop column bioreactor packed with Amberlite XAD-7, a slightly polor resin on which the lipase has been immobilized by adsorption. Various immobilization conditions as well as the properties of the immobilized lipase have been studied. The performance and the productivity of the bioreactor were evaluated as a function of the critical reaction parameters such as temperature, substrate concentration, and product inhibition. By using a 500-mL column bioreactor, 1.8 kg of optically pure (S)-(+)-Naproxen were produced after 1200 h of continuous operation with a slight loss of the enzymatic activity.     

Economic improvement of continuous pharmaceutical production via the optimal control of a multifeed bioreactor

Projections on the profitability of the pharmaceutical industry predict a large amount of growth in the coming years. Stagnation over the last 20 years in product development has led to the search for new processing methods to improve profitability by reducing operating costs or improving process productivity. This work proposes a novel multifeed bioreactor system composed of independently controlled feeds for substrate(s) and media used that allows for the free manipulation of the bioreactor supply rate and substrate concentrations to maximize bioreactor productivity and substrate utilization while reducing operating costs. The optimal operation of the multiple feeds is determined a priori as the solution of a dynamic optimization problem using the kinetic models describing the time‐variant bioreactor concentrations as constraints. This new bioreactor paradigm is exemplified through the intracellular production of beta‐carotene using a three feed bioreactor consisting of separate glucose, ethanol and media feeds. The performance of a traditional bioreator with a single substrate feed is compared to that of a bioreactor with multiple feeds using glucose and/or ethanol as substrate options. Results show up to a 30% reduction in the productivity with the addition of multiple feeds, though all three systems show an improvement in productivity when compared to batch production. Additionally, the breakeven selling price of beta‐carotene is shown to decrease by at least 30% for the multifeed bioreactor when compared to the single feed counterpart, demonstrating the ability of the multifeed reactor to reduce operating costs in bioreactor systems. © 2017 American Institute of Chemical Engineers Biotechnol. Prog., 33:902–912, 2017     

Sieve element unloading: cellular pathway, mechanism and control

The transport and distribution of phloem – mobile solutes is predominantly determined by transport processes located at the sink end of the source – transport – sink system. Transport across the sieve element boundary, sieve element unloading, is the first of a series of sink transport processes. Unloading of solutes from the sieve elements may follow an apo- or symplastic route. It is speculated that the unloading pathway is integrated with sink function and that apoplastic unloading is restricted to situations in which movement through the symplast is not compatible with sink function. These situations include axial transport and storage of osmotically active solutes against concentration and turgor gradients between the sieve elements and sink cells. Coupled with alteration in sink function, the cellular pathway of unloading can switch in stems and possibly other sinks. Experimental systems and approaches used to elucidate the mechanism of sieve element unloading are reviewed. Unloading fluxes to the apoplast can largely be accounted for by membrane diffusion in axial sinks. However, the higher fluxes in storage sinks suggests dependence on some form of facilitated transport. Proton sucrose symport is assessed to be a possible mechanism for facilitated efflux of solutes across the sieve element plasma membrane to the sink apoplast. Unloading through the symplast may occur by diffusion or mass flow. The latter mechanism serves to dissipate phloem water and hence prevent the potential elevation of sieve element turgor that would otherwise slow phloem import into the sink. The possibility of energised plasmodesmatal transport is raised. Sieve element unloading must be integrated with subsequent compartmentation and metabolism of the unloaded solute. Solute levels are an obvious basis for control of sieve element unloading, but are found to offer limited scope for a mass action mechanism. Apoplastic, cellular pathway, sieve element, solute transport, symplastic. Translated into a turgor signal, solute levels could regulate the rate of unloading, metabolism and compartmentation forming part of a turgor homeostat irrespective of the pathway of unloading.     

Essential,deadly, enigmatic: Polyamine metabolism and roles in fungal cells

Polyamines are essential metabolites found in all organisms. Intracellular polyamine levels are tightly maintained by biosynthesis, degradation, uptake and excretion processes that involve regulatory mechanisms – such as the antizyme inhibitory protein – that are conserved across the kingdoms of life, indicating that polyamine levels are critical to cell function. Nonetheless, the biochemical roles of polyamines and their involvement in numerous fundamental cellular processes including aging, cell cycle progression and growth only become apparent when polyamine homeostasis is perturbed. Thus, while polyamines are present in most cells and essential for cell growth, their biochemical functions are largely enigmatic. Studies in fungi have contributed to our basic understanding of polyamines, and might continue to bridge knowledge gaps regarding polyamine metabolism and cell function. Moreover, when considering the impact of fungi – directly or indirectly, for good or for ill – on human society, closing gaps in our understanding of polyamine functions in fungal physiology is an important goal in itself that might lead to the discovery of new targets for enhancing beneficial fungal interactions and diminishing those detrimental to crop and human health. To facilitate progress towards this prospect, here we appraise what is known about polyamine metabolism in fungi, how prevalent polyamines impact fungal physiology and metabolism, and how the levels of each polyamine are maintained in the fungal cell – thus pointing to how they might be perturbed.     

Optimization and mathematical modeling of the transtubular bioreactor for the production of monoclonal antibodies from a hybridoma cell line

This report describes the use of a transtubular bioreactor to study the relative effects of diffusion versus perfusion of medium on antibody production by a hybridoma cell line. The study was performed with a high-density cell culture maintained in a serum-free, low-protein medium for 77 days. It was determined that the reactor possessed a macro-mixing pattern residence time distribution similar to a continuous stirred tank reactor (CSTR). However, due to the arrangement of the medium lines in the reactor, the flow patterns for nutrient distribution consist of largely independent medium path lengths ranging from short to long. When operated with cyclic, reversing, transtubular medium flow, some regions of the reactor (with short residence times) are more accessible to medium than others (with long residence times). From this standpoint, the reactor can be divided into three regions: a captive volume, which consists of medium primarily delivered via diffusion; a lapped volume, which provides nutrients through unilateral convection; and a swept volume, which operates through bilateral convection. The relative sizes of these three volumes were modified experimentally by changing the period over which the direction of medium flow was reversed from 15 min (larger captive volume) to 9 h (larger swept volume). The results suggest that antibody concentration increases as the size of the diffusion-limited (captive) volume is increased to a maximum at around 30 min with a sharp decrease thereafter. As reflected by changes in measured consumption of glucose and production of lactate, no significant difference in cellular metabolism occurred as the reactor was moved between these different states. These results indicate that the mode of operation of the transtubular bioreactor may influence antibody productivity under serum-free, low-protein conditions with minimal effects on cellular metabolism.     

On-line measurements of culture fluorescence: Method and application

Summary In this paper a new probe allowing the measurement of NAD(P)H-dependent culture fluorescence in a bioreactor is presented. This sterilizable probe can be inserted in every bioreactor using a standard fitting of 25 mm. Under well defined conditions high specificity and sensitivity as well as high stability are further advantages of this probe. Application examples are given to demonstrate the operation possibilities of this fluorescence probe. In batch growth the culture fluorescence can be used for on-line estimation of biomass concentration. Metabolic alterations due to substrate of oxygen deficiency can easily be detected by fluorometric measurements. In kinetic studies the fluorescence probe is of great use because of a very small time delay.     

Scale down of recombinant protein production: a comparative study of scaling performance

A large bioreactor is heterogeneous with respect to concentration gradients of substrates fed to the reactor such as oxygen and growth limiting carbon source. Gradient formation will highly depend on the fluid dynamics and mass transfer capacity of the reactor, especially in the area in which the substrate is added. In this study, some production-scale (12 m³ bioreactor) conditions of a recombinant Escherichia coli process were imitated on a laboratory scale. From the large-scale cultivations, it was shown that locally high concentration of the limiting substrate fed to the process, in this case glucose, existed at the level of the feedpoint. The large-scale process was scaled down from: (i) mixing time experiments performed in the large-scale bioreactor in order to identify and describe the oscillating environment and (ii) identification of two distinct glucose concentration zones in the reactor. An important parameter obtained from mixing time experiments was the residence time in the feed zone of about 10 seconds. The size of the feed zone was estimated to 10%. Based on these observations the scale-down reactor with two compartments was designed. It was composed of one stirred tank reactor and an aerated plug flow reactor, in which the effect of oscillating glucose concentration on biomass yield and acetate formation was studied. Results from these experiments indicated that the lower biomass yield and higher acetate formation obtained on a large scale compared to homogeneous small-scale cultivations were not directly caused by the cell response to the glucose oscillation. This was concluded since no acetate was accumulated during scale-down experiments. An explanation for the differences in results between the two reactor scales may be a secondary effect of high glucose concentration resulting in an increased glucose metabolism causing an oxygen consumption rate locally exceeding the transfer rate. The results from pulse response experiments and glucose concentration measurements, at different locations in the reactor, showed a great consistency for the two feeding/pulse positions used in the large-scale bioreactor. Furthermore, measured periodicity from mixing data agrees well with expected circulation times for each impeller volume. Conclusions are drawn concerning the design of the scale-down reactor.     

Advantages in using non-isothermal bioreactors in bioremediation of water polluted by phenol by means of immobilized laccase from Rhus vernicifera

Laccase from Rhus vernicifera was immobilized on a polypropylene membrane chemically modified with chromic acid. Ethylenediamine and glutaraldehyde were used as spacer and bifunctional coupling agent, respectively. Phenol was used as substrate.To know how the immobilization procedures affected the enzyme reaction rate the catalytic behavior of soluble and insoluble laccase was studied under isothermal conditions as a function of pH, temperature and substrate concentration. From these studies, two main singularities emerged: (i) the narrower pH–activity profile of the soluble enzyme in comparison to that of the insoluble counterpart and (ii) the increase in pH and thermal stability of the insoluble enzyme.The laccase catalytic behavior was also studied in a non-isothermal bioreactor as a function of substrate concentration and size of the applied transmembrane temperature difference. It was found that, under non-isothermal conditions and keeping constant the average temperature of the bioreactor, the enzyme reaction rate linearly increased with the increase of the temperature difference.     

Control of continuous polyhydroxybutyrate synthesis using calorimetry and flow cytometry

The substrate-carbon flow can be controlled in continuous bioreactor cultures by the medium composition, for example, by the C/N ratio. The carbon distribution is optimal when a maximum fraction flows into the desired product and the residual is just sufficient to compensate for the dilution of the microbial catalyst. Undershooting of the latter condition is reflected immediately by changes in the Gibbs energy dissipation and cellular states. Two calorimetric measurement principles were applied to optimize the continuous synthesis of polyhydroxybutyrate (PHB) by Variovorax paradoxus DSM4065 during growth with constantly increasing supply rates of fructose or toxic phenol. Firstly, the changed slope of the heat production rate in a complete heat balanced bioreactor (CHB) indicated optimum carbon channeling into PHB. The extent of the alteration depended directly on the toxic properties of the substrate. Secondly, a flow through calorimeter was connected with the bioreactor as a "measurement loop." The optimum substrate carbon distribution was indicated by a sudden change in the heat production rate independent of substrate toxicity. The sudden change was explained mathematically and exploited for the long-term control of phenol conversion into PHB. LASER flow cytometry measurements distinguished between subpopulations with completely different PHB-content. Populations grown on fructose preserved a constant ratio of two subpopulations with double and quadruple sets of DNA. Cells grown on phenol comprised a third subpopulation with a single DNA set. Rising phenol concentrations caused this subpopulation to increase. It may thus be considered as an indicator of chemostress.     

Deep-bed solid state fermentation of sweet sorghum stalk to ethanol by thermotolerant Issatchenkia orientalis IPE 100

A solid state fermentation (SSF) of sweet sorghum stalk to ethanol was conducted in 250-mL flask using thermotolerant Issatchenkia orientalis IPE 100, and the optimal operation parameters were determined as 42°C fermentation temperature, 75% (w/w) water content, 2mm particle size and 3% (w/w) inoculation rate in 250-mL conical flask. When the SSF was scaled up from the flask to a 10-L bioreactor, temperature gradient in the substrate bed was observed due to heat accumulation in the bioreactor. The temperature gradient was dependent on both substrate depth and operation temperature. Due to high thermotolerance of the strain IPE 100, a deep-bed SSF of sweet sorghum stalk was developed in the bioreactor. The highest ethanol yield of 0.25 g-ethanol/g-dry stalk was obtained at 37°C with 15-20 cm substrate depth in the bioreactor. These results provided a great potential for large-scale deep-bed SSF in practice.     

Responses of intracellular cofactors to single and dual substrate limitations

The highly systematic responses of cellular cofactors to controlled substrate limitations of electron donor, electron acceptor, and both (dual limitation) were quantified using continuous-flow cultures of Pseudomonas putida. The results showed that the NADH concentration in the cells decreased gradually as the specific rate of electron-donor utilization (-q(d)) fell or increased systematically as oxygen limitation became more severe for fixed -q(d), while the NAD concentration was invariant. The NAD(H) responses demonstrated a common strategy; compensation for a low concentration of an externally supplied substrate by increasing (or decreasing) the concentration of its internal cosubstrate (or coproduct). The compensation was dramatic, as the NAD/NADH ratio showed a 24-fold modulation in response to depletion of dissolved oxygen (DO) or acetate. In the dual-limitation region, the compensating effects toward depletion of one substrate were damped, because the other substrate was simultaneously at low concentration. However, the NAD(H) responses minimized the adverse impact from substrate depletion on overall cell metabolism. Cellular contents of ATP, ADP, and P(i) were mostly affected by -q(d), such that the phosphorylation potential, ATP/ADP . P(i), increased as -q(d) fell due to depletion of acetate, DO, or both. Since the respiration rate should be slowed by high ATP/ADP . P(i), the cellular response seems to amplify an unfavorable environmental condition when oxygen is depleted. The likely reason for this apparent disadvantageous response is that the response of phosphorylation potential is more keenly associated with other aspects of metabolic control, such as for synthesis, which requires P(i) for production of phospholipids and nucleotides. (c) 1996 John Wiley & Sons, Inc.     

Enhanced production of L-(+)-lactic acid in chemostat by Lactobacillus casei DSM 20011 using ion-exchange resins and cross-flow filtration in a fully automated pilot plant controlled via NIR

Due to the lack of suitable in-process sensors, on-line monitoring of fermentation processes is restricted almost exclusively to the measurement of physical parameters only indirectly related to key process variables, i.e., substrate, product, and biomass concentration. This obstacle can be overcome by near infrared (NIR) spectroscopy, which allows not only real-time process monitoring, but also automated process control, provided that NIR-generated information is fed to a suitable computerized bioreactor control system. Once the relevant calibrations have been obtained, substrate, biomass and product concentration can be evaluated on-line and used by the bioreactor control system to manage the fermentation. In this work, an NIR-based control system allowed the full automation of a small-scale pilot plant for lactic acid production and provided an excellent tool for process optimization. The growth-inhibiting effect of lactic acid present in the culture broth is enhanced when the growth-limiting substrate, glucose, is also present at relatively high concentrations. Both combined factors can result in a severe reduction of the performance of the lactate production process. A dedicated software enabling on-line NIR data acquisition and reduction, and automated process management through feed addition, culture removal and/or product recovery by microfiltration was developed in order to allow the implementation of continuous fermentation processes with recycling of culture medium and cell recycling. Both operation modes were tested at different dilution rates and the respective cultivation parameters observed were compared with those obtained in a conventional continuous fermentation. Steady states were obtained in both modes with high performance on lactate production. The highest lactate volumetric productivity, 138 g L(-1) h(-1), was obtained in continuous fermentation with cell recycling.     

Evaluation of D-amino acid oxidase from Rhodotorula gracilis for the production of alpha-keto acids: a reactor system

The study reports on the development of a bioreactor for the production of alpha-keto acids from D,L- or D-amino acids using Rhodotorula gracilis D-amino acid oxidase. D-Amino acid oxidase was co-immobilized with catalase on Affi-Gel 10 matrix, and the reactor was operated as a continuous-stirred tank reactor (CSTR) or stirred tank with medium recycling conditions. The optimum substrate concentration and quantity of biocatalyst were determined (5 mM and 1.2 mg/L, respectively). Under optimum operating conditions, product formation was linearly related to both substrate and enzyme concentration, showing the system to be highly flexible. Under these conditions, in a stirred tank, over 90% conversion was achieved in 30 min with a maximum production of 0.23 g of pyruvic acid/day/enzyme units. Product was recovered by ion exchange chromatography. The operational stability of the reactor was high (up to 9.5 h of operation without loss of activity) and the inactivation half-life was not reached even after 18 h or 36 bioconversion cycles. This represents the first case of a reactor developed successfully with a D-amino acid oxidase. (c) 1994 John Wiley & Sons, Inc.     

A Bioreactor-Crystallizer for L-Malic Acid Production

A bioreactor with associated crystallizer for the accumulation of a highly concentrated slurry product has been developed and investigated. The transformation of Ca-fumarate to Ca-L-malate by the action of the fumarase of immobilized Brevibacterium flavum cells focussed on the performance of this newly-devised bioreactor-crystallizer system.

The following results were obtained

(1) The fumarase reaction in the bioreactor proceeded at a rate that was first-order in apparent substrate concentration.

(2) The reaction rate increased with the addition of Na₂-fumarate to the substrate solution.

(3) The reaction rate was independent of the substrate circulation rate and the initial substrate concentration in the crystallizer.

(4) Fumarase activity of immobilized B. flavum cells was stable after 10 repeated uses over a period of 10 days.

(5) Maximum concentration of the product, final conversion ratio of the substrate and the productivity of the bioreactor-crystallizer system were much higher than those for a conventional bioreactor using solubilized Ca-fumarate as a substrate.