Operation of a Benchtop Bioreactor

Fermentation systems are used to provide an optimal growth environment for many different types of cell cultures. The ability afforded by fermentors to carefully control temperature, pH, and dissolved oxygen concentrations in particular makes them essential to efficient large scale growth and expression of fermentation products. This video will briefly describe the advantages of the fermentor over the shake flask. It will also identify key components of a typical benchtop fermentation system and give basic instruction on setup of the vessel and calibration of its probes. The viewer will be familiarized with the sterilization process and shown how to inoculate the growth medium in the vessel with culture. Basic concepts of operation, sampling, and harvesting will also be demonstrated. Simple data analysis and system cleanup will also be discussed.     

Current industrial practice in solid state fermentations for secondary metabolite production: the Biocon India experience

Solid substrate fermentation at Biocon was originally envisaged for the production of enzymes, used in the food processing industry. The original process developed at Biocon was a hygienically designed automated tray culture process. Plants using this process still continue to run effectively at Biocon, and produce a variety of products meeting and exceeding FCC/JECFA specifications for food products. Biocon recently designed, developed and patented a new bioreactor, the PlaFractor™ (pronounced play-fractor) for carrying out fermentations that use solid matrices—a term covering both nutritive support matrices as well as non-nutritive matrices impregnated with medium.Using the PlaFractor™ process it is now possible to extend the use of solid matrix fermentation for the production of enzymes, biocontrol agents and pharmaceutical products, that require elaborate containment—under precisely defined conditions. The production takes place in computer controlled bioreactors, using complex fermentation control algorithms. All the operations of solid matrix fermentation, i.e. sterilization, cooling, inoculation, fermentation and process control, product recovery and post-fermentation sterilization, are all done in one single equipment, which was not hitherto possible. All the advantages of traditional solid state fermentation, over submerged fermentation, like low energy consumption, low water requirement, high mass transfer coefficient, no foaming, and high product concentrations are retained. In addition, techniques that are important to submerged fermentation, like fed-batch fermentation, process parameter profiling, air and media sterilization, operation under aseptic environments, and ease of handling, can now be easily applied to solid state fermentation, because of the way this bioreactor is designed.A production plant, built around this bioreactor has already been operating for more than a year.     

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.     

New developments in solid-state fermentation: II. Rational approaches to the design, operation and scale-up of bioreactors

Over the last decade there has been a significant improvement in understanding how to design, operate and scale-up solid-state fermentation bioreactors. The key to these advances has been the application of mathematical modeling techniques to describe the biological and transport phenomena within the system. This review focuses on the advances in understanding that have come from this modeling work, and the insights it has given us into bioreactor design, operation and scale-up. It also highlights two promising bioreactor designs that have emerged over the last decade or so. For processes in which the substrate bed must remain static throughout the fermentation, the most promising design is the Zymotis design of ORSTOM at Montpellier, France, which involves closely spaced internal heat transfer plates within a packed-bed bioreactor. For those processes in which mixing can be tolerated, the stirred bioreactor developed at INRA, in Dijon, France, has been successfully demonstrated at scales of 1–25 t of substrate. Theoretical work suggests that mathematical models will be useful tools in the scale-up process, however, there are no reports that they have been used in the development of any current large-scale process. Rather, the models have been validated against data obtained from laboratory-scale bioreactors. There is an urgent need to test the accuracy and robustness of the models by applying them within real process development.     

Cell culture processes for monoclonal antibody production

Animal cell culture technology has advanced significantly over the last few decades and is now generally considered a reliable, robust and relatively mature technology. A range of biotherapeutics are currently synthesized using cell culture methods in large scale manufacturing facilities that produce products for both commercial use and clinical studies. The robust implementation of this technology requires optimization of a number of variables, including (1) cell lines capable of synthesizing the required molecules at high productivities that ensure low operating cost; (2) culture media and bioreactor culture conditions that achieve both the requisite productivity and meet product quality specifications; (3) appropriate on-line and off-line sensors capable of providing information that enhances process control; and (4) good understanding of culture performance at different scales to ensure smooth scale-up. Successful implementation also requires appropriate strategies for process development, scale-up and process characterization and validation that enable robust operation and ensure compliance with current regulations. This review provides an overview of the state-of-the art technology in key aspects of cell culture, e.g., generation of highly productive cell lines and optimization of cell culture process conditions. We also summarize the current thinking on appropriate process development strategies and process advances that might affect process development.Key words: monoclonal antibody, expression systems, cell line engineering, cell culture process development, optimization scale-up and technology transfer, process advances     

Cell culture processes for monoclonal antibody production

Animal cell culture technology has advanced significantly over the last few decades and is now generally considered a reliable, robust and relatively mature technology. A range of biotherapeutics are currently synthesized using cell culture methods in large scale manufacturing facilities that produce products for both commercial use and clinical studies. The robust implementation of this technology requires optimization of a number of variables, including 1) cell lines capable of synthesizing the required molecules at high productivities that ensure low operating cost; 2) culture media and bioreactor culture conditions that achieve both the requisite productivity and meet product quality specifications; 3) appropriate on-line and off-line sensors capable of providing information that enhances process knowledge; and 4) good understanding of culture performance at different scales to ensure smooth scale-up. Successful implementation also requires appropriate strategies for process development, scale-up and process characterization and validation that enable robust operation that is compliant with current regulations. This review provides an overview of the state-of-the art technology in key aspects of cell culture, e.g., engineering of highly productive cell lines and optimization of cell culture process conditions. We also summarize the current thinking on appropriate process development strategies and process advances that might affect process development.     

An integrated microprocessor-based fermenter control system

An integrated microprocessor-based fermenter controller was developed in 1980 for an operational environment at Cetus Corp. The main goals in the design and construction of the system were (1) to facilitate scale-up; (2) to provide flexibility and high performance for optimizing fermentation processes; and (3) to be cost-effective for 15 in-house systems. It was also developed to work in conjunction with a laboratory minicomputer for on-line optimization experiments. The controller controls temperature, agitation, dissolved oxygen, pH, and foam throughout each fermentation run without manual intervention. The feedback control parameters have been optimized to provide very accurate control over a wide range of setpoint conditions and under rapidly changing metabolic conditions such as induced during an Escherichia coli batch run. The controller has also been configured to monitor, display, and record each of the controlled variables; support the interactive operator console; and communicate with the laboratory computer. In over 4 years of operation, these systems have met the design goals and have proven to be very reliable. The controller is described, its operational performance presented, and a typical fermentation run delineated.     

Scale-up of whey fermentation in a pilot-scale fermenter

Summary The scale-up of a whey fermentation byKluyveromyces fragilis was carried out in order to reproduce on a larger scale (100-l fermenter) the results obtained on a smaller scale (15-l fermenter).Using a standard procedure for inoculum development and medium pasteurization, the effects of mixing and lactose concentration on yeast growth, lactose consumption, COD reduction and dissolved oxygen have been studied.The most successful operation for this fermentation was found to be associated with high stirring rates and low lactose concentrations, since the process was controlled by both oxygen and lactose concentrations.     

通过参数相关性分析对发酵控制策略在植酸酶高密度发酵中的作用探讨

为了优化植酸酶高密度发酵条件,有必要获取在发酵过程中由于控制策略引起有关参数的实时变化及其关联性.本研究利用传感器对植酸酶工程菌高密度发酵过程进行数据在线采集,通过改变转速、接种量与补料甘油,探讨三方面控制因素对高密度发酵产酶过程参数具体影响及各参数变化之间的相关性,建立起与转速-细胞密度-溶氧-乳酸相关的发酵罐内外环...     

Kinetics of efrotomycin synthesis in a synthetic fermentation medium

Experiments using a soluble, chemically defined fermentation medium provided important knowledge about the kinetics of efrotomycin biosynthesis. Equivalent titers were obtained in a batch process in both shaker flasks and fermentors. By extended feeding of both monosodium glutamate and glycerol at elevated temperatures, in combination with sulphuric acid pH control, the specific production rate was increased 2.8 fold and overall production rate was improved 5-fold. If the monosodium glutamate was fed too fast, then ammonium accumulated with indications of strong repression of efrotomycin biosynthesis at concentrations above 6 mM. In contrast to the complex medium used for this process, the chemically define medium was completely insensitive to changes in sterilization conditions.     

Scale-up effects on kinetic parameters and on predictions of a yeast recycle continuous ethanol fermentation model incorporating loss of cell viability

The scale-up effects on kinetic parameters and on predictions of a yeast recycle continuous ethanol fermentation model incorporating loss of cell viability were evaluated. The average level of cell viability estimated for large scale was similar to that estimated for small scale, although with a major standard deviation. The values of specific rate of cell viability loss were equal for the two scales. These results were due to the utilization of the same aeration rate for both scales, one of the main factors for cell-viability maintenance. The kinetic parameters were not significantly affected by the scale-up of the fermentation process. Major differences were observed for the maximum specific growth rate and for maximum ethanol concentrations for which, growth and ethanol production are totally inhibited. The scale-up did not result in lack of fit of the mathematical model to the experimental data.     

Bioconversion of avermectin into 27-OH avermectin

Summary The bioconversion of avermectin to its 27-hydroxy derivative is achieved withNocardia autotrophica subsp.canberrica. The approach of increasing bioconversion productivity rather than efficiency was adopted in these studies. Process improvement studies focused on the physico-chemical conditions of the fermentation, examined initially at the shake-flask scale. Bioconversion yields were affected by pH, substrate concentration, time of substrate addition, substrate solubilization, carbon to nitrogen ratio, and medium strength. Optimization of these parameters resulted in a 8-fold process improvement. During pre scale-up studies, the sensitivity of this bioconversion to the antifoam employed was demonstrated and lard oil was selected as giving the best results. Additional process changes were required during scale-up efforts in larger vessels, including replacement of the original substrate solvent with dimethylsulfoxide.     

Development of Media and Automated Liquid Fermentation Methods to Produce Desiccation-Tolerant Propagules ofTrichoderma harzianum

A suitable medium was developed from modified Richard's medium plus V8 juice (RM8) to produce high levels of desiccation-tolerant conidia ofTrichoderma harzianumstrain 1295-22. The addition of 9% (v/v) glycerol to RM8 improved both biomass production and desiccation tolerance of the conidia ofT. harzianum.This medium was then used in a laboratory scale fermenter (1.5 liter) to determine optimal operating conditions. The optimal temperature for conidial production and desiccation tolerance improvement in the fermenter was 32°C when dissolved oxygen was maintained at 50% saturation of air, and the stirring rate was 1000 revolutions per minute. The initial water potential of the medium (with 9% glycerol) was −3.7 MPa, the pH was 6, and neither was controlled during fermentation. Changes in medium pH and dissolved oxygen were associated with the stages of morphological development and conidiation. The pH of the medium decreased concurrently with germ-tube elongation and mycelium development and then increased to 6.0–6.2 at phialide formation. Intensive conidiation occurred at pH 6.3–6.5 and reached its maximal level at 6.9–7.1. Changes in pH values could be used as indicators to monitor the morphological development and conidiation ofT. harzianumduring fermentation. The use of a 48-h-old culture inoculum, rather than conidial inoculum, to start fermentation reduced the time required to complete the shift from vegetative growth to phialide formation. Intensive conidiation occurred immediately after the addition of culture inoculum and reached maximum levels within 68 h of fermentation. Dry weight of biomass increased with the duration of fermentation and was greatest at 96 h. However, no improvements in conidia/gram and CFU/gram were achieved after 72 h of fermentation. The desiccation tolerance of conidia harvested at 72 or 96 h was significantly (P = 0.05) greater than that of conidia harvested at 48 h of fermentation. Results obtained from this study could be used for further scale-up of the fermentation process.     

On-line measurement of gas production rates

Gas evolution rates represent an important variable to track in biological and certain electrochemical processes. Accurate gas flow rate sensors exist for gas streams possessing a pressure head, such as when pressurized air or oxygen is delivered to a fermentation process. However, these devices impose pressure heads that can inhibit gas production and, therefore, yield false measurements. Examples of effected processes would include electrochemical production of a gas at the electrode (e.g., electrolysis) or anaerobic fermentation (e.g., anaerobic production of methane). In this work, we present an on-line gas measurement technique that measures on-line gas production from an anaerobic microbial process that is continuously fed simulated food waste over a 6-month period. Commentary is given on the sensor's accuracy and ease of use within the context of long-term operation, ability to measure both low and high gas production rates, as well as its potential for process control and system-health monitoring.     

Fehlermöglichkeiten der Gelöstsauerstoffmessung beim Betrieb von Bioreaktoren

A review of errors, which can influence the measured data of electrochemical oxygen sensors (OS) in fermentation technique is presented. The specifities of various sensor constructions are pointed out. References are given for selection of sensors to application in fermenters. Influences on the measured values can take place by fermentation conditions, arrangement of sensors in the fermenter and composition of the fermentation broth. The oxygen measurement in the multi-phase system of fermentation fluids can cause a remarkable deviation of the measured values to the real ones. Practical hints are given for use, calibration and sterilization of OS. Restricting conditions for measurements with this sensors are enumerated.     

Studies on Oxygen Transfer in Submerged Fermentations

In conventional shaken culture system, control of oxygen supply is performed by changing liquid volume in flasks and it necessarily introduces variation in the effectiveness of agitation and in the partial pressure of carbon dioxide. In jar or tank culture system, also, the changes in mechanical agitation and in the flow rate of air for control of aeration induce similar problems. It is impossible, therefore, to isolate the effects of oxygen on microbial metabolism from these accompanying ones. Hence, there is a basic requirement of making clear distinction among them, and in this paper the effects of agitation and carbon dioxide on product formation are presented in glutamic acid fermentation using the apparatus of controlling the level of dissolved oxygen throughout the fermentation.

To obtain fundamental knowledge required for attaining adequate aeration, the rate of oxygen demand in glutamic acid fermentation was discussed in connection with its fermentation rates. On the basis of specific rates, rates of change per unit mass of cells, glutamic acid fermentation was found to fall in the process pattern of Gaden’s type II, in which a constant rate of oxygen demand was sustained for a considerable time. On the basis of volumetric rates, rates of change per unit volume of broths, oxygen demand was recognized to be correlated with growth, sugar utilization and product formation, and it was pointed out particularly that the oxygen demand was closedly related with sugar utilization. In the particular cases where rapid utilization of sugar occurred, therefore, oxygen deficiency was liable to be evoked being unable to fill the growing oxygen demand. This finding might be useful for scale-up studies or process design.     

发酵条件对毕赤酵母表达重组人干扰素ω糖基化的影响

发酵条件是影响毕赤酵母 (P .pastoris)表达外源重组糖蛋白时糖基化的重要因素。通过菌体浓度、起始pH值、甲醇诱导浓度和周期、装液量等摇瓶发酵实验 ,研究不同发酵条件对毕赤酵母表达分泌型重组人干扰素ω(rhIFNω)过程中糖基化的影响 ;同时 ,在连续培养过程中考察pH值变化对rhIFNω糖基化的影响和分批发酵过程中rhIFNω糖基化的变化。结果表明 ,控制菌体密度 250g L(WCW)、起始pH值 6 0、装液量小于 30mL、甲醇诱导浓度 15g L、甲醇诱导 3次 (每 24h诱导一次 )等发酵条件 ,有利于摇瓶发酵过程中rhIFNω的糖基化 ;控制pH值 70～75可促进rhIFNω的糖基化 ;分批发酵过程中 ,糖基化与非糖基化rhIFNω的含量有同比变化趋势 ,但糖基化rhIFNω所占比例明显低于摇瓶发酵实验的结果 ,其原因有待进一步研究。     

Scaleable downstream recovery of nematodes used as biopesticides.

This study assesses the suitability of sieving as a scaleable technique for the separation of adult nematodes from infective juveniles, the latter is an effective bioinsecticide whereas the former is waste material resulting from the fermentation process. Batch and semibatch experiments using conventional flow-assisted wet sieving and a novel cross-flow sieving technique were used to study the separation of juveniles from adult nematodes. The experiments were carried out using small-scale devices and the data were analyzed in terms of the screen effectiveness factor. The results were used to identify the sieve size and operating conditions for optimum juvenile recovery. It was found that, for a given species of nematode, optimum recovery was achieved when sieving was carried out in the cross-flow mode, the maximum recovery being a function of the size of the screen. Industrial-scale self-cleaning equipment capable of large-scale continuous screening was used to confirm the capacity of the small-scale operation for scale-up. Experimental results with this unit showed that in continuous operation sieving time is an additional parameter that influences separation performance.     

Application of Modeling to Scale-up Dissolution in Pharmaceutical Manufacturing

Liquid mixing scale-up in pharmaceutical industry has often been based on empirical approach in spite of tremendous understanding of liquid mixing scale-up in engineering fields. In this work, we attempt to provide a model-based approach to scale-up dissolution process from a 2 l lab-scale vessel to a 4,000 l scale vessel used in manufacturing. Propylparaben was used as a model compound to verify the model predictions for operating conditions at commercial scale that would result in similar dissolution profile as observed in lab scale. Geometric similarity was maintained between both of the scales to ensure similar mixing characteristics. We utilized computational fluid dynamics (CFD) to ensure that the operating conditions at laboratory and commercial scale will result in similar power per unit volume (P/V). Utilizing this simple scale-up criterion of similar P/V across different scales, results obtained indicate fairly good reproducibility of the dissolution profiles between the two scales. Utilization of concepts of design of experiments enabled summarizing scale-up results in statistically meaningful parameters, for example −90% dissolution in lab scale at a given time under certain operating conditions will result in 75–88% at commercial scale with 95% confidence interval when P/V is maintained constant across the two scales. In this work, we have successfully demonstrated that scale-up of solid dissolution can be done using a systematic process of lab-scale experiments followed by simple CFD modeling to predict commercial-scale experimental conditions.     

Scale-up from shake flasks to fermenters in batch and continuous mode with Corynebacterium glutamicum on lactic acid based on oxygen transfer and pH

Scale-up from shake flasks to fermenters has been hampered by the lack of knowledge concerning the influence of operating conditions on mass transfer, hydromechanics, and power input. However, in recent years the properties of shake flasks have been described with empirical models. A practical scale-up strategy for everyday use is introduced for the scale-up of aerobic cultures from shake flasks to fermenters in batch and continuous mode. The strategy is based on empirical correlations of the volumetric mass transfer coefficient (k(L) a) and the pH. The accuracy of the empirical k(L) a correlations and the assumptions required to use these correlations for an arbitrary biological medium are discussed. To determine the optimal pH of the culture medium a simple laboratory method based on titration curves of the medium and a mechanistic pH model, which is solely based on the medium composition, is applied. The effectiveness of the scale-up strategy is demonstrated by comparing the behavior of Corynebacterium glutamicum on lactic acid in shake flasks and fermenters in batch and continuous mode. The maximum growth rate (micro(max) = 0.32 h(-1)) and the oxygen substrate coefficient (Y O2 /S= 0.0174 mol/l) of C. glutamicum on lactic acid were equal for shake flask, fermenter, batch, and continuous cultures. The biomass substrate yield was independent of the scale, but was lower in batch cultures (Y(X/S) = 0.36 g/g) than in continuous cultures (Y(X/S) = 0.45 g/g). The experimental data (biomass, respiration, pH) could be described with a simple biological model combined with a mechanistic pH model.