Large scale production of phage antibody libraries using a bioreactor

One of the limitations of the use of phage antibody libraries in high throughput selections is the production of sufficient phage antibody library at the appropriate quality. Here, we successfully adapt a bioreactor-based protocol for the production of phage peptide libraries to the production of phage antibody libraries. The titers obtained in the stirred-tank bioreactor are 4 to 5 times higher than in a standard shake flask procedure, and the quality of the phage antibody library produced is indistinguishable to that produced using standard procedures as assessed by Western blotting and functional selections. Availability of this protocol will facilitate the use of phage antibody libraries in high-throughput scale selections.     

Large scale production of phage antibody libraries using a bioreactor

One of the limitations of the use of phage antibody libraries in high throughput selections is the production of sufficient phage antibody library at the appropriate quality. Here, we successfully adapt a bioreactor-based protocol for the production of phage peptide libraries to the production of phage antibody libraries. The titers obtained in the stirred-tank bioreactor are 4 to 5 times higher than in a standard shake flask procedure, and the quality of the phage antibody library produced is indistinguishable to that produced using standard procedures as assessed by Western blotting and functional selections. Availability of this protocol will facilitate the use of phage antibody libraries in high-throughput scale selections.     

Recent developments in bioreactor scale production of bacterial polyhydroxyalkanoates

Bioprocess and Biosystems Engineering - Polyhydroxyalkanoates (PHAs) are biological plastics that are sustainable alternative to synthetic ones. Numerous microorganisms have been identified as PHAs...     

Power consumption and maximum energy dissipation in a milliliter‐scale bioreactor

Mean power consumption and maximum local energy dissipation were measured as function of operating conditions of a milliliter‐scale stirred tank bioreactor (V = 12 mL) with a gas‐inducing impeller. A standard laboratory‐scale stirred tank bioreactor (V = 1,200 mL) with Rushton turbines was used as reference. The measured power characteristics (Newton number as function of Reynolds number) were the same on both scales. The changeover between laminar and turbulent flow regime was observed at a Reynolds number of 3,000 with the gas‐inducing stirrer on a milliliter‐scale. The Newton number (power number) in the turbulent flow regime was 3.3 on a milliliter‐scale, which is close to values reported for six‐blade Rushton turbines of standard bioreactors. Maximum local energy dissipation (ε_max) was measured using a clay/polymer flocculation system. The maximum local energy dissipation in the milliliter‐scale stirred tank bioreactor was reduced compared with the laboratory‐scale stirred tank at the same mean power input per unit mass (ε_ø), yielding ε_max/ε_ø ≈ 10 compared with ε_max/ε_ø ≈ 16. Hence, the milliliter‐scale stirred tank reactor distributes power more uniformly in the reaction medium. These results are in good agreement with literature data, where a decreasing ε_max/ε_ø with increasing ratio of impeller diameter to reactor diameter is found (d/D = 0.7 compared with d/D = 0.4). Based on these data, impeller speeds can now be easily adjusted to achieve the same maximum local energy dissipation at different scales. This enables a more reliable and robust scale‐up of bioprocesses from milliliter‐scale to liter‐scale reactors. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2010     

Continuous production of lignin peroxidase by immobilized Phanerochaete chrysosporium in a pilot scale bioreactor

Lignin peroxidase was continuously produced by nylon-web or polyurethane immobilized Phanerochaete chrysosporium ATCC 24725 in a modified Biostate E® bioreactor, agitated either with the air and oxygen flow alone or in combination with a mechanical stirrer. Lignin peroxidase production started rapidly, and activities as high as ∼600 U l⁻¹ were reached as early as in 3 days. At best a total activity yield of ∼10 000 U was obtained during one week's continuous production with the maximum activity of ∼750 U l⁻¹ with nylon-web immobilized fungus, veratryl alcohol as an activator, and 2,2-dimethylsuccinate as buffer, although the relatively inexpensive benzyl alcohol and sodium tartrate peformed satisfactorily as the activator and buffer, respectively.     

Succinic acid production from Bacteroides fragilis: process optimization and scale up in a bioreactor

We report the effect of different physiological and nutritional parameters on succinic acid production from Bacteroides fragilis. This strain initially produced 0.70gL(-1) of succinic acid in 60h. However, when process optimization was employed, 5.4gL(-1) of succinic acid was produced in medium consisting of glucose (1.5%); tryptone (2.5%); Na(2)CO(3) (1.5%), at pH 7.0, when inoculated with 4% inoculum and incubated at 37 degrees C, 100rpm for 48h. A marked enhancement in succinic acid production was observed when the optimized conditions were employed in a 10L bioreactor. A total of 12.5gL(-1) of succinic acid was produced in 30h. This is approximately 12-fold increase in succinic acid production when compared to the initial un-optimized medium production. This enhancement in succinic acid production may be due to the control of CO(2) supply and the impeller speed. This is also resulted in the reduction of the production time. The present study provides useful information to the industrialists seeking environmentally benign technology for the production of bulk biomolecules through manipulation of various chemical parameters.     

Multistrain probiotic production by co‐culture fermentation in a lab‐scale bioreactor

Most commercial probiotic products intended for pharmaceutical applications consist of combinations of probiotic strains and are available in various forms. The development of co‐culture fermentation conditions to produce probiotics with the correct proportion of viable microorganisms would reduce multiple operations and the associated costs. The aim of this study was to develop a fermentation medium and process to achieve biomass comprising the desired proportion of two probiotic strains in co‐culture. Initially, a quantification medium was developed, and the method was optimized to allow the quantification of each strain's biomass in a mixture. The specific growth rates of Lactobacillus delbrueckii spp. bulgaricus and Lactobacillus plantarum were determined in media with different carbon sources. The inoculum volume was optimized to achieve equal proportion of biomass in co‐culture fermentation in test tubes. Next, fermentation was carried out in a 3‐L bioreactor. A biomass concentration of 2.06 g/L, with L. delbrueckii spp. bulgaricus and L. plantarum in the ratio of 47%:53% (by weight), was achieved with concomitant production of 12.69 g/L of lactic acid in 14 h. The results show that with careful manipulation of process conditions, it is possible to achieve the desired proportion of individual strains in the final biomass produced by co‐culture fermentation. This process may serve as a model to produce multistrain probiotic drugs at industrial scale.     

Bioprocess development for kefiran production by Lactobacillus kefiranofaciens in semi industrial scale bioreactor

Lactobacillus kefiranofaciens is non-pathogenic gram positive bacteria isolated from kefir grains and able to produce extracellular exopolysaccharides named kefiran. This polysaccharide contains approximately equal amounts of glucose and galactose. Kefiran has wide applications in pharmaceutical industries. Therefore, an approach has been extensively studied to increase kefiran production for pharmaceutical application in industrial scale. The present work aims to maximize kefiran production through the optimization of medium composition and production in semi industrial scale bioreactor. The composition of the optimal medium for kefiran production contained sucrose, yeast extract and K₂HPO₄ at 20.0, 6.0, 0.25 g L⁻¹, respectively. The optimized medium significantly increased both cell growth and kefiran production by about 170.56% and 58.02%, respectively, in comparison with the unoptimized medium. Furthermore, the kinetics of cell growth and kefiran production in batch culture of L. kefiranofaciens was investigated under un-controlled pH conditions in 16-L scale bioreactor. The maximal cell mass in bioreactor culture reached 2.76 g L⁻¹ concomitant with kefiran production of 1.91 g L⁻¹.     

Microbial enzyme production in a membrane bioreactor

Summary Erwinia chrysanthemi cells were used to study the possibility of producing bacterial enzymes in a bioreactor coupled with a membrane filtration unit. Continuous fermentations with total cell recycle failed to give good production of pectate lyase (PL). Enzymatic, mechanical and physico-chemical damages were involved in this phenomenon. With a sequential recycle mode, we obtained productivity of 1.5 units·h^–1·1^–1 with a high PL concentration. Protease accumulation occurred when the bioreactor was coupled to a filtration unit. Moreover we have observed no loss of activity due to high shear stress caused by pumping. Offprint requests to: P. Boyaval     

Application of bioreactor systems for large scale production of horticultural and medicinal plants

Automation of micropropagation via organogenesis or somatic embryogenesis in a bioreactor has been advanced as a possible way of reducing costs. Micropropagation by conventional techniques is typically a labour-intensive means of clonal propagation. The paper describes lower cost and less labour-intensive clonal propagation through the use of modified air-lift, bubble column, bioreactors (a balloon-type bubble bioreactor), together with temporary immersion systems for the propagation of shoots, bud-clusters and somatic embryos. Propagation of Anoectochilus, apple, Chrysanthemum, garlic, ginseng, grape, Lilium, Phalaenopsis and potato is described. In this chapter, features of bioreactors and bioreactor process design specifically for automated mass propagation of several plant crops are described, and recent research aimed at maximizing automation of the bioreactor production process is highlighted.     

Techno-economic modeling and assessment of cultivated meat: Impact of production bioreactor scale

Increases in global meat demands cannot be sustainably met with current methods of livestock farming, which has a substantial impact on greenhouse gas emissions, land use, water consumption, and farm animal welfare. Cultivated meat is a rapidly advancing technology that produces meat products by proliferating and differentiating animal stem cells in large bioreactors, avoiding conventional live-animal farming. While many companies are working in this area, there is a lack of existing infrastructure and experience at commercial scale, resulting in many technical bottlenecks such as scale-up of cell culture and media availability and costs. In this study, we evaluate theoretical cultivated beef production facilities with the goal of envisioning an industry with multiple facilities to produce in total 100,000,000 kg of cultured beef per year or ~0.14% of the annual global beef production. Using the computer-aided process design software, SuperPro Designer®, facilities are modeled to create a comprehensive analysis to highlight improvements that can lower the cost of such a production system and allow cultivated meat products to be competitive. Three facility scenarios are presented with different sized production reactors; ~42,000 L stirred tank bioreactor (STR) with a base case cost of goods sold (COGS) of $35/kg, ~211,000 L STR with a COGS of $25/kg, and ~262,000 L airlift reactor (ALR) with a COGS of $17/kg. This study outlines how advances in scaled up bioreactors, alternative bioreactor designs, and decreased media costs are necessary for commercialization of cultured meat products.     

Large scale production of the copper enzyme peptidylglycine monooxygenase using an automated bioreactor

Rat PHM (peptidylglycine alpha-hydroxylating monooxygenase; EC 1.14.17.3) expressed in CHO DG44 cells as a recombinant protein (rat PHMcc, residues 42-356 cloned in the pCIS vector, A.S. Kolhekar, H.T. Keutman, R. E. Mains, A.S.W. Quon, B.A. Eipper, Biochemistry 36 (1997) 10901-10909), was produced in two different bioreactors, a Cellmax 100 (B1) and an Accusyst-MiniMax (B2). B2 contains features not present in B1, which contribute to environmental control, and ease of operation, and was more successful at producing high quality PHM than B1 in both yield (B1: 5mg/day, B2: 12-15 mg/day), activity (B1: 12-20 micromol O(2)/min/mg, B2: 24-36 micromol O(2)/min/mg), and viability (B1: <6 months, B2: indefinite). Additionally, B1 exhibited clipping at Ser 61, and a decline in quality late in the run. PHM from B2 was of consistent quality and homogeneity throughout the run. The increased yield and purity made possible collection of visible spectra of the Cu(II) sites, and mass spectrometric data not previously available.     

Gas phase acetaldehyde production in a continuous bioreactor

The gas phase continuous production of acetaldehyde was studied with particular emphasis on the development of biocatalyst (alcohol oxidase on solid phase support materials) for a fixed bed reactor. Based on the experimental results in a batch bioreactor, the biocatalysts were prepared by immobilization of alcohol oxidase on Amberlite IRA-400, packed into a column, and the continuous acetaldehyde production in the gas phase by alcohol oxidase was performed. The effects of the reaction temperature, flow rates of gaseous stream, and ethanol vapor concentration on the performance of the continuous bioreactor were investigated. (c) 1993 John Wiley & Sons, Inc.     

Biological hydrogen production using a membrane bioreactor

A cross-flow membrane was coupled to a chemostat to create an anaerobic membrane bioreactor (MBR) for biological hydrogen production. The reactor was fed glucose (10,000 mg/L) and inoculated with a soil inoculum heat-treated to kill non-spore-forming methanogens. Hydrogen gas was consistently produced at a concentration of 57-60% in the headspace under all conditions. When operated in chemostat mode (no flow through the membrane) at a hydraulic retention time (HRT) of 3.3 h, 90% of the glucose was removed, producing 2200 mg/L of cells and 500 mL/h of biogas. When operated in MBR mode, the solids retention time (SRT) was increased to SRT = 12 h producing a solids concentration in the reactor of 5800 mg/L. This SRT increased the overall glucose utilization (98%), the biogas production rate (640 mL/h), and the conversion efficiency of glucose-to-hydrogen from 22% (no MBR) to 25% (based on a maximum of 4 mol-H(2)/mol-glucose). When the SRT was increased from 5 h to 48 h, glucose utilization (99%) and biomass concentrations (8,800 +/- 600 mg/L) both increased. However, the biogas production decreased (310 +/- 40 mL/h) and the glucose-to-hydrogen conversion efficiency decreased from 37 +/- 4% to 18 +/- 3%. Sustained permeate flows through the membrane were in the range of 57 to 60 L/m(2) h for three different membrane pore sizes (0.3, 0.5, and 0.8 microm). Most (93.7% to 99.3%) of the membrane resistance was due to internal fouling and the reversible cake resistance, and not the membrane itself. Regular backpulsing was essential for maintaining permeate flux through the membrane. Analysis of DNA sequences using ribosomal intergenic spacer analysis indicated bacteria were most closely related to members of Clostridiaceae and Flexibacteraceae, including Clostridium acidisoli CAC237756 (97%), Linmingia china AF481148 (97%), and Cytophaga sp. MDA2507 AF238333 (99%). No PCR amplification of 16s rRNA genes was obtained when archaea-specific primers were used.     

Ethanol production in horizontal bioreactor

Summary The rate of continuous alcohol fermentation by a mixture of free and immobilized yeast cells was found to be higher in a horizontal flow channel reactor than in a vertical column reactor under the same operational conditions. This higher fermentation rate in the horizontal reactor was attributed to accumulation of yeast cells in the reactor by free sedimentation and incomplete mixing in the direction of liquid flow. It was estimated that most of the ethanol in the horizontal bioreactor was produced by free cells in suspended or settled states. The relatively low ethanol production by the immobilized yeast cells on the ethanol production was considered due to higher product inhibition of fermentation rate within the support.     

Stochastic identification of bioreactor process exhibiting input multiplicity

Bioreactor systems involve complex biochemical reactions, which make the systems highly non-linear in nature. Developing model based controllers for such processes require mathematical representations, which are simple, yet capable of capturing the non-linear process characteristics. Continuous bioreactor falls under the class of non-linear systems that exhibit input multiplicity in the optimal operating region, i.e., the operating region where identical outputs are obtained for multiple inputs. Linear modeling techniques are not useful for the referred class of systems for obvious reasons. Even for non-linear modeling techniques, the real bottleneck is to capture the bell-shaped parabolic structure of steady state characteristics exhibited by these systems. The stochastic approach of modeling, which is based on process input/output time-series data, is very useful for this purpose. The aim of this paper is to address the stochastic modeling issues related to bioreactor processes. In this work, three efficient modeling techniques have been studied, viz. block oriented NARMAX structure (Pearson and Pottmann in J Process Control 10:301-315, 2000), Bootstrap structure detection for NARMAX model (Kukreja et al. in Int J Control 77(2):132-143, 2004) and Wavelet-NARMAX model (Billings and Wei in Int J Syst Sci 36(3):137-152, 2005).     

Gas phase ethyl acetate production in a batch bioreactor

Gas phase ethyl acetate production was studied using a porcine pancreatic lipase powder. It was observed that gaseous ethyl acetate was produced from gaseous ethanol and acetic acid. Accordingly, the effects of amount of lipase powder, gaseous ethanol and acetic acid concentrations, and reaction temperature on the performance of a batch bioreactor were investigated. Apparent Michaelis-Menten constant of ethanol was 0.163 [μM] and there was no inhibition by ethanol over the range investigated. As acetic acid concentration increased, ethyl acetate production increased to a maximum, then decreased, thus suggesting the inhibition effects by acetic acid. Over the reaction temperature of 25–55?°C, activation energy was calculated as 3.93 kcal/gmol and initial reaction rate was obtained as follows: r?=?75.7 exp(?1975.7/T) [μM/mg of lipase/hr]     

High-rate acetic acid production in a shallow flow bioreactor

Summary The production of acetic acid in a new type of bioreactor was investigated. The bioreactor featured a shallow, horizontal flow of medium under a bacterial film of Acetobacter aceti M7. The volumetric productivity increased with increase in the specific liquid surface area. The maximum productivity was 31.7 g acetic acid·l^-1 per hour for a specific liquid surface area of 10.7 cm^-1 and the exit acetic acid concentration of 57.6 g·l^-1. The productivity was considerably higher than values surveyed in the literature regarding the acetic acid concentration of normal vinegar (about 45 g·l^-1).     

Pectate lyase production byBacillus subtilis in a membrane bioreactor

Summary An environmental strain ofBacillus subtilis was cultivated in a membrane bioreactor. Microbial cells were trapped by an upright membrane module fitted in the vessel reactor. Cell biomass and pectate lyase activity were increased about 5–6 times in comparison to a batch process. Clogging of the membrane module appears to be a major problem.     

Selective fengycin production in a modified rotating discs bioreactor

Production of lipopeptides fengycin and surfactin in rotating discs bioreactor was studied. The effects of rotation velocity and the addition of agitators between the discs on volumetric oxygen transfer coefficient k _L a were firstly studied in model media. Then the production of lipopeptides was also studied at different agitation conditions in the modified bioreactor (with agitators). The effect of agitation on dissolved oxygen, on submerged and immobilized biomass, on lipopeptide concentrations and yields and on the selectivity of the bioreaction was elucidated and discussed. The proposed modified rotating discs bioreactor allowed to obtain high fengycin concentrations (up to 787 mg L^?1), but also better selectivity of the bioreaction towards fengycin (up to 88 %) and better yields of fengycin per glucose (up to 62.9 mg g^?1), lipopeptides per glucose (up to 71.5 mg g^?1), fengycin per biomass (up to 309 mg g^?1) and lipopeptides per biomass (up to 396 mg g^?1) than those reported in the literature. Highest fengycin production and selectivity were obtained at agitation velocity of 30 min^?1. The proposed non-foaming fermentation process could contribute to the scale-up of lipopeptide fermentors and promote the industrial production of fengycin. The proposed bioreactor and bioprocess could be very useful also for the production of other molecules using bioprocesses requiring bubbleless oxygen supply.