Optimization of the Ethanol Recycling Reflux Extraction Process for Saponins Using a Design Space Approach

A solvent recycling reflux extraction process for Panax notoginseng was optimized using a design space approach to improve the batch-to-batch consistency of the extract. Saponin yields, total saponin purity, and pigment yield were defined as the process critical quality attributes (CQAs). Ethanol content, extraction time, and the ratio of the recycling ethanol flow rate and initial solvent volume in the extraction tank (RES) were identified as the critical process parameters (CPPs) via quantitative risk assessment. Box-Behnken design experiments were performed. Quadratic models between CPPs and process CQAs were developed, with determination coefficients higher than 0.88. As the ethanol concentration decreases, saponin yields first increase and then decrease. A longer extraction time leads to higher yields of the ginsenosides Rb₁ and Rd. The total saponin purity increases as the ethanol concentration increases. The pigment yield increases as the ethanol concentration decreases or extraction time increases. The design space was calculated using a Monte-Carlo simulation method with an acceptable probability of 0.90. Normal operation ranges to attain process CQA criteria with a probability of more than 0.914 are recommended as follows: ethanol content of 79–82%, extraction time of 6.1–7.1 h, and RES of 0.039–0.040 min⁻¹. Most of the results of the verification experiments agreed well with the predictions. The verification experiment results showed that the selection of proper operating ethanol content, extraction time, and RES within the design space can ensure that the CQA criteria are met.     

Unit Operation Optimization for the Manufacturing of Botanical Injections Using a Design Space Approach: A Case Study of Water Precipitation

Quality by design (QbD) concept is a paradigm for the improvement of botanical injection quality control. In this work, water precipitation process for the manufacturing of Xueshuantong injection, a botanical injection made from Notoginseng Radix et Rhizoma, was optimized using a design space approach as a sample. Saponin recovery and total saponin purity (TSP) in supernatant were identified as the critical quality attributes (CQAs) of water precipitation using a risk assessment for all the processes of Xueshuantong injection. An Ishikawa diagram and experiments of fractional factorial design were applied to determine critical process parameters (CPPs). Dry matter content of concentrated extract (DMCC), amount of water added (AWA), and stirring speed (SS) were identified as CPPs. Box-Behnken designed experiments were carried out to develop models between CPPs and process CQAs. Determination coefficients were higher than 0.86 for all the models. High TSP in supernatant can be obtained when DMCC is low and SS is high. Saponin recoveries decreased as DMCC increased. Incomplete collection of supernatant was the main reason for the loss of saponins. Design space was calculated using a Monte-Carlo simulation method with acceptable probability of 0.90. Recommended normal operation region are located in DMCC of 0.38–0.41 g/g, AWA of 3.7–4.9 g/g, and SS of 280–350 rpm, with a probability more than 0.919 to attain CQA criteria. Verification experiment results showed that operating DMCC, SS, and AWA within design space can attain CQA criteria with high probability.     

Characterization of a Saccharomyces cerevisiae fermentation process for production of a therapeutic recombinant protein using a multivariate Bayesian approach

The principle of quality by design (QbD) has been widely applied to biopharmaceutical manufacturing processes. Process characterization is an essential step to implement the QbD concept to establish the design space and to define the proven acceptable ranges (PAR) for critical process parameters (CPPs). In this study, we present characterization of a Saccharomyces cerevisiae fermentation process using risk assessment analysis, statistical design of experiments (DoE), and the multivariate Bayesian predictive approach. The critical quality attributes (CQAs) and CPPs were identified with a risk assessment. The statistical model for each attribute was established using the results from the DoE study with consideration given to interactions between CPPs. Both the conventional overlapping contour plot and the multivariate Bayesian predictive approaches were used to establish the region of process operating conditions where all attributes met their specifications simultaneously. The quantitative Bayesian predictive approach was chosen to define the PARs for the CPPs, which apply to the manufacturing control strategy. Experience from the 10,000 L manufacturing scale process validation, including 64 continued process verification batches, indicates that the CPPs remain under a state of control and within the established PARs. The end product quality attributes were within their drug substance specifications. The probability generated with the Bayesian approach was also used as a tool to assess CPP deviations. This approach can be extended to develop other production process characterization and quantify a reliable operating region. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:799–812, 2016     

Extraction of crude polysaccharides from Duchesnea indica (Andrews) Focke: optimization by response surface methodology

A full set of optimization procedure was applied to the extraction of anti-viral polysaccharides from Duchesnea indica (Andrews) Focke. By Plackett–Burman factorial design, three parameters (extraction time, extraction temperature, and ratio of water to raw material) were identified as significant to the extraction yield. However, no significant parameters had been identified for antiviral activity. A three-level-three-factor Box–Behnken factorial design was then employed to further optimize the extraction condition. The experimental data were fitted to a second-order polynomial equation using multiple regression analysis and also examined using appropriate statistical methods. This led to the construction of a response surface indicating the optimal values for each parameter and response studied. Concerning the extraction yield, an extraction at 98.51?ºC for 6.16 h with a ratio of water to raw material of 30.94 mL/g was found to be optimal. Under the optimized conditions, the experimental yield was 6.430 ± 0.078%, which was well matched with the predicted yield of 6.509%.     

Comparison of different extraction methods of polysaccharides from cup plant (Silphium perfoliatum L.)

The purpose of the present research was to compare the effects of four extraction methods on the extraction yields, physicochemical characteristics, and antioxidant activities of polysaccharides from the cup plant (Silphium perfoliatum L.) (CPPs). The extraction methods included the hot water extraction method (HEM), ultrasonic-assisted extraction method (UEM), enzyme-assisted extraction method (EEM), and the ultrasonic-enzyme-assisted extraction method (UEEM). Four corresponding CPP extracts, HEM-CPPs, UEM-CPPs, EEM-CPPs, and UEEM-CPPs, were obtained. The results indicated that there were notable differences between the extraction methods regarding the yield, average molecular weight, uronic acid content, monosaccharide proportions, and the antioxidant activities of the CPPs. HEM-CPPs were extracted with the lowest yield (6.44%). EEM-CPPs had the largest extraction yield (9.87%) and the most notable antioxidant abilities of ferric reducing power and free radical scavenging activity. According to correlation analysis, the higher antioxidant abilities of EEM-CPPs might be due to their smaller average molecular weight and a higher content of uronic acid than those of the other extracted CPPs. Therefore, EEM could serve as a promising technique for extracting CPPs.     

响应面法优化微波辅助提取发酵虫草菌丝体多糖工艺

为优化发酵虫草菌粉多糖的微波辅助提取工艺,在单因素实验基础上,以液固比、微波功率以及提取时间为自变量,多糖提取率为响应值,采用中心组合设计的方法,研究各自变量及其交互作用对多糖提取率的影响。利用SAS软件和响应面分析相结合的方法对发酵虫草菌粉多糖的微波辅助提取工艺进行优化,确定了微波辅助提取多糖的最佳条件：液固比值12．2,微波功率650．5W,提取时间11．8min,在此条件下,多糖提取率达到6．41％。采用此法提取的虫草菌丝体多糖,当质量浓度为1mg／mL时,对二苯代苦味肼基自由基（DPPH）清除率达到76％。     

Optimization of extraction process of Glycyrrhiza glabra polysaccharides by response surface methodology

Experimental design was used to investigate the effect of three parameters (extraction time, extraction number and ratio of water to raw material) on polysaccharides yields. The ranges of the factors investigated were 3.5–4.5 h for extraction time (X₁), 4–6 for extraction number (X₂), and 25–35 for ratio of water to raw material (X₃). The statistical analysis of the experiment indicated that extraction time and ratio of water to raw material had significant effect on Glycyrrhiza glabra polysaccharides yields. The central composite design showed that polynomial regression models were in good agreement with the experimental results with the coefficients of determination of 0.924 for Glycyrrhiza glabra polysaccharides yield. The optimal condition for Glycyrrhiza glabra polysaccharides yield within the experimental range of the variables studied was at 4.3 h, 6, and 35. At this condition, the predicted yield of polysaccharides extracted was 3.6%.     

超声辅助酸水解提取山里红叶中牡荆素的工艺优化

采用正交法优化山里红叶中牡荆素的超声辅助提取工艺。通过盐酸浓度、提取时间、固液比、超声功率、超声温度、乙醇浓度6种影响因素的单因素实验,研究它们与牡荆素提取得率之间的规律趋势;应用正交设计优化试验,研究盐酸浓度、提取时间、固液比和超声功率对山里红叶提取牡荆素得率影响大小,并确定最佳提取工艺。研究结果表明：当盐酸浓度为2 mol·L^-1、提取时间为40 min,固液比为1：20、超声功率为500 W、超声温度为50℃、乙醇浓度为50%时,效果最佳,得率为2.603 mg·g^-1;盐酸浓度具有较大显著性,且各因素影响顺序为：盐酸浓度 > 超声功率> > 提取时间 > 固液比。     

A fast and simple approach to optimize the unit operation high pressure homogenization - a case study for a soluble therapeutic protein in E. coli

Escherichia coli is one of the most commonly used host organisms for the production of recombinant biopharmaceuticals. E. coli is usually characterized by fast growth on cheap media and high productivity, but one drawback is its intracellular product formation. Product recovery from E. coli bioprocesses requires tedious downstream processing (DSP). A typical E. coli DSP for an intracellular product starts with a cell disruption step to access the product. Different methods exist, but a scalable process is usually achieved by high pressure homogenization (HPH). The protocols for HPH are often applied universally without adapting them to the recombinant product, even though HPH can affect product quantity and quality. Based on our previous study on cell disruption efficiency, we aimed at screening operational conditions to maximize not only product quantity, but also product quality of a soluble therapeutic protein expressed in E. coli. We screened for critical process parameters (CPPs) using a multivariate approach (design of experiments; DoE) during HPH to maximize product titer and achieve sufficient product quality, based on predefined critical quality attributes (CQAs). In this case study, we were able to gain valuable knowledge on the efficiency of HPH on E. coli cell disruption, product release and its impact on CQAs. Our results show that HPH is a key unit operation that has to be optimized for each product.     

响应面法优化微波辅助提取枇杷叶中黄酮类化合物

为充分利用枇杷叶,研究微波辅助乙醇浸提法从枇杷叶中提取黄酮类化合物的工艺。首先研究了影响提取效果的因素:不同体积分数的乙醇溶液、料液比、时间及微波功率。在单因素试验基础上利用响应面分析法,确定了各因素与总黄酮得率之间的关系,并以总黄酮得率为响应值做响应面和等高线图。研究表明,枇杷叶中黄酮类化合物提取最佳工艺为乙醇体积分数50%,料液比1∶30,提取时间3 min,微波功率500 W,最佳条件下总黄酮得率为2.04%,与理论推导值2.07%相比,误差为1.4%,黄酮类化合物响应方程的回归分析表明此方法合理可行。本研究对枇杷叶总黄酮提取优化的研究为进一步探讨枇杷叶的深度开发提供了理论参考依据,并为枇杷叶总黄酮的生物活性研究提供材料。     

响应面优化超声辅助法提取拐枣种子中二氢杨梅素的工艺

二氢杨梅素和杨梅素是拐枣种子中的重要成分。通过超声辅助法从拐枣种子中提取二氢杨梅素，采用单因素法考察乙醇体积分数、超声辐照功率、提取温度、液料比和超声辐照时间影响参数的基础上，并选用Box-Behnken响应面设计法分析建立了超声辐照功率、超声辐照时间和液料比的二次多项式模型，优化提取工艺。结果得到超声辅助法提取拐枣种子中二氢杨梅素的最佳工艺参数为：乙醇体积分数为60%、超声辐照功率140 W、超声辐照时间30 min、液料比20.5 mL·g^-1，提取温度40℃。在此最佳条件下，二氢杨梅素得率为2.14±0.09 mg·g^-1。本提取方法简单快速，效率高，有利于拐枣资源的综合加工利用。     

Microwave assisted extraction of ursolic acid and oleanolic acid from Ocimum sanctum

Present study deals with the microwave assisted extraction (MAE) of ursolic acid (UA) and oleanolic acid (OA) from Ocimum sanctum leaves. UA and OA have been reported to possess significant medicinal properties. Various experimental parameters such as selection of solvent, solvent composition, irradiation time, microwave power, solid to solvent ratio, preleaching time and number of cycles were investigated to optimize the extraction process. Under optimum conditions of irradiation time (3 min), microwave power (272 W), solid to solvent ratio (1:30), preleaching time (10 min), maximum UA and OA has been extracted in one extraction cycle with ethanol: water (80:20) as a solvent. Maximum 86.76 and 89.64% of UA and OA was extracted under above mentioned optimized experimental conditions. MAE was also compared with the batch and ultrasound assisted extraction (UAE) method. As compared to batch and UAE, higher extraction yield of these important phytochemicals have been obtained through MAE in only 3 min.     

Single-laboratory validation for the determination of caffeic acid and seven caffeoylquinic acids in sweet potato leaves

A single-laboratory validation study was conducted on an HPLC method for the detection and quantification of caffeic acid (CA) and seven species of caffeoylquinic acids (CQAs) in lyophilized sweet potato leaves. The procedure for extraction of the analytes from the matrix and the HPLC conditions for the efficient separation of CA and CQAs were optimized. In the proposed method, a relative response factor to one of the CQAs (5-CQA) was used to quantify the others. The method performed well in terms of precision when carried out on five different days and demonstrated Horwitz ratio (HorRat) scores ranging from 0.5 to 1.0 for all analytes, which were well within the limits of performance acceptability. Accuracy testing at three levels showed an overall recovery of 94% when duplicated on five different days. Moreover, a stability study revealed that all analytes in both standard solution and sample extract were stable for 28?days.     

正交试验法优化桑叶多糖提取工艺

以脱除黄酮的桑叶为原料,采用热水浸提法提取桑叶多糖,研究了提取温度、提取时间、料液比、水溶液pH和提取次数对桑叶多糖得率的影响,通过正交实验优化了提取工艺条件。结果表明,在提取次数为2次条件下,桑叶多糖最佳提取工艺条件为提取温度100℃、提取时间4 h、提取液pH7、料液比(原料:提取液,g/mL)1:30,多糖得率为2.74%。该工艺稳定,桑叶多糖得率高,易于工业化生产。     

响应面法优化超声提取绿茶茶多酚工艺

利用响应面法对超声提取绿茶荼多酚的工艺条件进行优化,在单因素试验的基础上,根据中心组合设计原理采用三因素三水平的响应面分析法,依据回归分析确定最优提取工艺条件。结果表明,其最佳工艺条件为：液料比为40．2mL／g,超声功率为476W,提取时间为15．1min,采用该工艺条件,茶多酚的提取得率达到10．312％,通过响应面法得到一个能较好预测试验结果的模型方程。     

响应曲面法优化马尾松中莽草酸的超声提取工艺

以马尾松松针为原料,采用超声波提取法从松针粉中提取莽草酸,通过考察料液比((VH2O∶m松针粉,mL:g)、提取时间、提取温度及超声波功率等因素对松针中总莽草酸含量的影响,并在单因素试验的基础上,选取料液比、提取时间、超声波功率3个变量,进行Box-Behnken中心组合设计优化,获得马尾松松针中莽草酸的最佳提取工艺参数为料液比1∶26,提取时间为46min,超声波功率为359 W,此条件下莽草酸的提取率为1.948%。     

超声辅助低共熔溶剂提取沙棘籽粕多酚的工艺优化

以一系列低共熔溶剂为提取剂,采用超声波辅助法从沙棘籽粕中提取多酚。在单因素试验结果基础上,利用Box-Behnken实验设计,运用响应面分析法对影响沙棘籽粕多酚得率的主要因素（超声功率、超声时间、超声温度）进行优化。结果表明,沙棘籽粕多酚最佳提取工艺条件为：以含水量为30%的氯化胆碱-草酸低共熔溶剂为最佳提取剂,液料比为14∶1,超声功率420 W,超声时间56 min,超声温度44℃。在此条件下,多酚得率为3.31±0.008%。对比试验发现：氯化胆碱-草酸低共熔溶剂对沙棘籽粕多酚的得率明显优于传统溶剂;与热回流提取相比,超声提取法具有明显的优势。     

响应面法优化厚朴中和厚朴酚与厚朴酚的提取工艺研究简

为探讨响应面法优化厚朴中和厚朴酚与厚朴酚的提取工艺。以溶媒比、乙醇浓度、提取时间为自变量,和厚朴酚与厚朴酚总提取百分含量作为因变量,通过对自变量各水平的多元线性回归及二项式拟合,用响应面法选取较佳工艺,并进行预测分析。确定最佳提取工艺为溶媒比60 mL·g^-1、乙醇浓度为72%、提取时间78 min,和厚朴酚与厚朴酚总提取百分含量达2.29%。说明响应面法优选厚朴中和厚朴酚与厚朴酚成分提取工艺,方法简单,结果可靠。     

响应面法优化低温豆粕大豆分离蛋白提取工艺

采用响应面分析法(RSM)对低温豆粕大豆分离蛋白(soybean protein isolated,SPI)的碱提工艺进行优化。在单因素实验的基础上,选取了影响SPI提取率的4个关键因素(pH、温度、时间和液料比)进行四因素五水平的中心组合旋转实验设计(CCRD)。通过RSM建立了响应值(SPI提取率)与各影响因素之间的回归方程,并获得了SPI的最优提取条件:pH 8.5,提取温度55℃,提取时间42.8 min,料水比1∶9.7(g/mL),此条件下SPI提取率预测值为37.12%,与实验值(36.69%)的误差为1.16%。将一次碱提后残渣进行二次碱提,二次提取率为10.16%。2次碱提上清液等电点沉淀的蛋白沉淀率分别为84.03%和85.84%。     

Optimization of ultrasound-assisted aqueous two-phase system extraction of polyphenolic compounds from Aronia melanocarpa pomace by response surface methodology

Aronia melanocarpa berries are abundant in polyphenolic compounds. After juice production, the pomace of pressed berries still contains a substantial amount of polyphenolic compounds. For efficient utilization of A. melanocarpa berries and the enhancement of polyphenolic compound yields in Aronia melanocarpa pomace (AMP), total phenolics (TP) and total flavonoids (TF) from AMP were extracted, using ultrasound-assisted aqueous two-phase system (UAE-ATPS) extraction method. First, the influences of ammonium sulfate concentration, ethanol–water ratio, ultrasonic time, and ultrasonic power on TP and TF yields were investigated. On this basis, process variables such as ammonium sulfate concentration (0.30–0.35?g?mL^?1), ethanol–water ratio (0.6–0.8), ultrasonic time (40–60?min), and ultrasonic power (175–225?W) were further optimized by implementing Box–Benhnken design with response surface methodology. The experimental results showed that optimal extraction conditions of TP from AMP were as follows: ammonium sulfate concentration of 0.324?g?mL^?1, ethanol–water ratio of 0.69, ultrasonic time of 52?min, and ultrasonic power of 200?W. Meanwhile, ammonium sulfate concentration of 0.320?g?mL^?1, ethanol–water ratio of 0.71, ultrasonic time of 50?min, and ultrasonic power of 200?W were determined as optimum extraction conditions of TF in AMP. Experimental validation was performed, where TP and TF yields reached 68.15?±?1.04 and 11.67?±?0.63?mg?g^?1, respectively. Close agreement was found between experimental and predicted values. Overall, the present results demonstrated that ultrasound-assisted aqueous two-phase system extraction method was successfully used to extract total phenolics and flavonoids in A. melanocarpa pomace.