Growth monitoring and control in complex medium: a case study employing fed-batch penicillin fermentation and computer-aided on-line mass balancing

To broaden the practicality of on-line growth monitoring and control, its application in fedbatch penicillin fermentation using high corn steep liquor (CSL) concentration (53 g/L) is demonstrated. By employing a calculation method that considers the vagaries of CSL consumption, overall and instantaneous carbon-balancing equations are successfully used to calculate, on-line, the cell concentration and instantaneous specific growth rate in the penicillin production phase. As a consequence, these equations, together with a feedback control strategy, enable the computer control of glucose feed and maintenance of the preselected production-phase growth rate with error less than 0.002 h(-1).     

Tandem mass spectrometry for on-line fermentation monitoring

Summary Membrane introduction mass spectrometry has been employed for on-line determination of the major products and volatile metabolites ofBacillus polymyxa fermentation. Samples were introduced into the mass spectrometer via a direct insertion membrane probe in which the aqueous solution flowed past a membrane located in the ion source of the mass spectrometer. Concentrations of the products 2,3-butanediol, acetoin, ethanol and acetic acid in fermentation broth were measured by tandem mass spectrometry after permeation through the membrane and ionization by chemical ionization. External standards were employed for quantification and a large linear response range was available for each of the major products observed. Dissolved CO₂ and O₂, as well as CO₂ in the off gases, were also monitored on-line by mass spectrometry. The use of tandem mass spectrometry has allowed the identification of products that were not previously known to be present in measurable amounts.     

An on-line sampling system for fermentation monitoring using membrane inlet mass spectrometry (MIMS): application to phenoxyacetic acid monitoring in penicillin fermentation

A sampling system for on-line monitoring of organic compounds of low volatility in complex fermentation media uses membrane inlet mass spectrometry (MIMS). A Syringe pump draws a continuous flow of microfiltered broth from the reactor and circulates it after acidification through a membrane inlet, in which a membrane is the only interface between the sample and the high vacuum of a mass spectrometer. All operations run automatically, i.e., sampling, acidification measurement, and calibration. The on-stream acidification enables MIMS monitoring of carboxylic acids, as they must be undissociated in order to pass the hydrophobic membrane. The performance of the monitoring system was tested by measurements of standard solutions of phenoxyacetic acid (POAA, the sie chain precursor of penicillin-V) as well as on POAA during 200 h penicillin-V fermentation. During the entire fermentation POAA was monitored n low millimolar concentrations with high accuracy and fast response to step changes in POAA concentration. Tandem mass spectrometry (MS/MS) allowed direct identification of peaks in the mass spectrum of the broth that were not accounted for by POAA. These peaks were identified as SO(2) and SCO. (c) 1994 John Wiley & Sons, Inc.     

Application of balancing methods in modeling the penicillin fermentation

This paper shows the application of elementary balancing methods in combination with simple kinetic equations in the formulation of an unstructured model for the fed-batch process for the production of penicillin. The rate of substrate uptake is modeled with a Monod-type relationship. The specific penicillin production rate is assumed to be a function of growth rate. Hydrolysis of penicillin to penicilloic acid is assumed to be first order in penicillin. In simulations with the present model it is shown that the model, although assuming a strict relationship between specific growth rate and penicillin productivity, allows for the commonly observed lag phase in the penicillin concentration curve and the apparent separation between growth and production phase (idiophase-trophophase concept). Furthermore it is shown that the feed rate profile during fermentation is of vital importance in the realization of a high production rate throughout the duration of the fermentation. It is emphasized that the method of modeling presented may also prove rewarding for an analysis of fermentation processes other than the penicillin fermentation.     

Computational algorithms for optimal feed rates for a class of fed-batch fermentation: Numerical results for penicillin and cell mass production

Based upon the general characteristics of the optimal feed rate profiles presented in an earlier article, efficient computational algorithms have been developed for fed-batch fermentation processes described by four or less mass balance equations. These algorithms make computations of optimal substrate feed rate profiles straight forward and simple for various fed-batch cultures for such products as antibiotics, amino acids, enzymes, alcohols, and cell mass. Numerical examples of penicillin fermentation and bacterial cell mass production are given in detail, illustrating the use of these algorithms.     

On-line adaptive control of a fed-batch fermentation of Saccharomyces cerevisiae

The feasibility of applying an adaptive control technique to a fermentation process is investigated. The nonlinear, time-variant parameters of a fermentation process were estimated on-line as a series of linearized describing matrices. The matrices were used to update a suboptimal feedback law which controlled the process in real time over the linear region. Experiments were performed on a small-scale fully instrumented fermenter with the online, real-time adaptive control package. Results are presented for both single- and multivariable control, and indicate successful control of yeast cell growth.     

On-line membrane inlet mass spectrometry for feed-back control of precursor concentration in penicillin fermentation

Summary A sampling system which enables on-line measurements of the precursor phenoxyacetic acid (POAA) in penicillin fermentation by membrane inlet mass spectrometry is presented and its capacity for feed-back regulation of POAA to a low predefined concentration in a penicillin-V fermentation over 150 hours is demonstrated. The system measures alternately filtered sample and standard solution in a measuring cycle which is shorter than the response time of membrane inlet mass spectrometry (MIMS) but sufficiently long to decide whether the concentration of POAA in the sample is higher or lower than in the standard solution at set point concentration. The decision is used for on-off regulation of the addition of POAA.     

On-line monitoring and control of acetone-butanol fermentation by membrane-sensor mass spectrometry

A mass spectrometry (MS) membrane sensor was developed and applied to on-line product measurement in acetone-butanol fermentation. The sensor facilitated the monitoring of acetone, butanol, ethanol, H₂ and CO₂, and single-compound calibration curves for both acetone and butanol showed a linear relationship between the product concentration and the MS response. However, when an actual fermentation was monitored, the product concentration calculated from the MS response was smaller than the concentration determined by gas chromatography, and the relationship between the response and the product concentration was nonlinear. It was found that large amounts of gases (H₂, CO₂) entering the MS analyzation chamber were causing a ‘space charge effect’, which resulted in an MS response ceiling. The problem could be resolved by reducing the surface area of the sensor membrane. Under some fermentation conditions, a by-product, n-butyl butyrate, was produced, and this interfered with the measurement of butanol due to a peak overlapping effect. However, it was found that this could be compensated for by using an empirical equation. Application of the MS membrane sensor in a fed batch culture of acetone-butanol fermentation resulted in successful control of the butanol concentration.     

Enhanced process monitoring of fed-batch penicillin cultivation using time-varying and multivariate statistical analysis

On-line monitoring of penicillin cultivation processes is crucial to the safe production of high-quality products. In the past, multiway principal component analysis (MPCA), a multivariate projection method, has been widely used to monitor batch and fed-batch processes. However, when MPCA is used for on-line batch monitoring, the future behavior of each new batch must be inferred up to the end of the batch operation at each time and the batch lengths must be equalized. This represents a major shortcoming because predicting the future observations without considering the dynamic relationships may distort the data information, leading to false alarms. In this paper, a new statistical batch monitoring approach based on variable-wise unfolding and time-varying score covariance structures is proposed in order to overcome the drawbacks of conventional MPCA and obtain better monitoring performance. The proposed method does not require prediction of the future values while the dynamic relations of data are preserved by using time-varying score covariance structures, and can be used to monitor batch processes in which the batch length varies. The proposed method was used to detect and identify faults in the fed-batch penicillin cultivation process, for four different fault scenarios. The simulation results clearly demonstrate the power and advantages of the proposed method in comparison to MPCA.     

Modeling and advanced control of recombinant Zymomonas mobilis fed-batch fermentation

This work presents the development of an unstructured kinetic model incorporating the differing degrees of product, substrate, and pH inhibition on the kinetic rates of ethanol fermentation by recombinant Zymomonas mobilis CP4:pZB5 for growth on two substrates. Product inhibition was observed to start affecting the specific growth rate at an ethanol concentration of 20 g/L and the specific productivity at about 35-40 g/L. Specific growth rate was also shown to be more sensitive to inhibition by lowered pH as well. A model for the inhibition of two competing substrates' cellular uptake via membrane transport is proposed. Inhibition functions and model parameters were determined by fitting experimental data to the model. The model was utilized in a nonlinear model predictive control (NMPC) algorithm to control the product concentration during fed-batch fermentation to offset the inhibitory effects of product inhibition. Using the optimal feeding policy determined online, the volumetric productivity of ethanol was improved 16.6% relative to the equivalent batch operation when the final ethanol concentration was reached.     

Intact cell mass spectrometry as a progress tracking tool for batch and fed-batch fermentation processes

Penicillin production during a fermentation process using industrial strains of Penicillium chrysogenum is a research topic permanently discussed since the accidental discovery of the antibiotic. Intact cell mass spectrometry (ICMS) can be a fast and novel monitoring tool for the fermentation progress during penicillin V production in a nearly real-time fashion. This method is already used for the characterization of microorganisms and the differentiation of fungal strains; therefore, the application of ICMS to samples directly harvested from a fermenter is a promising possibility to get fast information about the progress of fungal growth. After the optimization of the ICMS method to penicillin V fermentation broth samples, the obtained ICMS data were evaluated by hierarchical cluster analysis or an in-house software solution written especially for ICMS data comparison. Growth stages of a batch and fed-batch fermentation of Penicillium chrysogenum are differentiated by one of those statistical approaches. The application of two matrix-assisted laser desorption/ionization time-of-flight (MALDI–TOF) instruments in the linear positive ion mode from different vendors demonstrated the universal applicability of the developed ICMS method. The base for a fast and easy-to-use method for monitoring the fermentation progress of P. chrysogenum is created with this ICMS method developed especially for fermentation broth samples.     

Novel calibration method for mass spectrometers for on-line gas analysis. Set-up for the monitoring of a bacterial fermentation

A set-up procedure for the minimisation of signal noise of a capillary inlet mass spectrometer system, enabling direct use of data without noise filtering or drift correction, is described. A reliable calibration method was developed, involving standard calibration mixtures determined by the extreme vertices design. This novel method was shown to be the most accurate in comparison with a number of commonly used methods. These procedures enabled reliable on-line fermenter headspace gas analysis. With a relatively inexpensive mass spectrometer, monitoring of a fermentation and accurate estimation of oxygen uptake rate, carbon dioxide evolution rate, respiratory quotient and biomass concentration was possible.     

Combining yield coefficients and exit-gas analysis for monitoring of the baker's yeast fed-batch fermentation

Baker's yeast is one of the micro-organisms that is studied most in literature. Therefore, a lot of knowledge on the biochemical pathways and corresponding yield coefficients is available. This knowledge is combined with measurements of oxygen and carbon dioxide in the exit-gas to determine the coefficients appearing in the stoichiometric equations. In this manner, two measurements are sufficient to yield on-line estimates for biomass, glucose, ethanol and the specific growth rate, and information about the (ill-defined) nitrogen source NH_q. This is not possible if the yield coefficients are not included in the estimation procedure. A sensitivity analysis illustrates that this estimation scheme is rather insensitive to uncertainties on the yield coefficients.     

Implementation of a thermal biosensor in a process environment: on-line monitoring of penicillin V in production-scale fermentations.

The production of penicillin V was monitored in 0.5 m3 and 160 m3 bioreactors. The thermal biosensor was an enzyme thermistor modified for split-flow analysis. The heat signal generated in the enzyme column was corrected for any nonspecific heat with the use of an identical but inactive reference column. The on-line monitoring was performed in the fermentation pilot plant and in a fermentation plant of Novo Nordisk A/S. Immobilized beta-lactamase was used to monitor three consecutive 0.5 m3 penicillin fermentations. Broth samples were continuously filtered through a tangential flow filtration unit in a sterile external loop. The on-line penicillin V values were 10% higher than those obtained by off-line HPLC analysis. Alternatively a polypropylene filtration probe was inserted into a 160 m3 bioreactor and samples were withdrawn at 0.5 ml/min. The same experiments were repeated with purified and immobilized penicillin V acylase. The on-line penicillin V values obtained with this enzyme correlated very well with those from HPLC analysis. The on-line monitoring was controlled and analysed by a software program written in Labtech Notebook.     

Enhanced cellulase production using Solka Floc in a fed-batch fermentation

Summary Use of a fed-batch mode of cultivation of T. reesei has permitted high concentrations of substrate to be consumed. This has resulted in the production of high titre cellulase preparations around 30 FPU/ml at high volumetric productivities (177 IU/L.hr).Perhaps the most obvious area for major improvement in the process of cellulose utilization is the production of cellulase enzyme for hydrolysis of wood and agricultural residues. It has been estimated that some 50% of the cost of producing glucose from cellulosic material is attributable to enzyme production alone (Perez, et al., 1980). Improvements in the area would therefore have a dramatic impact, and are of paramount importance if economical hydrolysis processes are to be realized. The first major thrust in the area has been the development of improved mutant strains of T. reesei, free from catabolite repression and capable of constitutive cellulase production (Montenecourt and Eveleigh, 1977; Gallo, 1982).While this effort continues to develop further high yielding mutants, improvement must also come from developments in fermentation techniques. A major advance is the use of fed-batch cultivation, which provides a means of avoiding the agitation and aeration difficulties, as well as repression effects encountered with high substrate concentration batch fermentation. This report briefly compares batch and fed-batch operation over a range of substrate concentrations.     

Evaluation of bacterial contamination in a fed-batch alcoholic fermentation process

Alcoholic fermentation by a commercial baker's yeast in a fed-batch process with cell recycling and high-test molasses as substrate was strongly inhibited by Lactobacillus fermentum CCT 1407 after a few recycles. When total acidity (mainly lactic acid) exceeded 4.8 g/l broth it seriously interfered with yeast bud formation and viability and above 6.0 g/l it decreased alcoholic efficiency.     

Simulation of penicillin production in fed-batch cultivations using a morphologically structured model

A mathematical model is formulated to describe trends in biomass and penicillin formation as well as substrate consumption for fed-batch cultivations. The biomass is structured into three morphological compartments, and glucose and corn steep liquor are considered as substrates for growth. Penicillin formation is assumed to take place in the subapical compartment and in the growing region of the hyphal compartment. Furthermore, it is inhibited by glucose. Model parameters are estimated using an evolutionary algorithm and fitting the model to a standard fed-batch cultivation. The model is validated on experimental data from three different fed-batch cultivations, including two repeated fed-batch cultivations. The model predictions show good agreement with the measurements of biomass and pencillin concentrations for all fed-batch cultivations. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 56: 593-604, 1997.     

Design and simulation of a fuzzy controller for fed-batch yeast fermentation

In baker's yeast fermentation, the process is non-linear and the response of the system to changes in glucose feeding has a very long delay time. Therefore, a conventional system can not give satisfactory results. In this paper, a fuzzy controller designed to control a fed-batch fermenter is presented. The fuzzy controller uses Respiratory Quotient (RQ) as a controller input and produces glucose feeding rate as control variable. The controller has been tested on a simulated fed-batch fermenter. The results show that the maximum yeast production is possible by keeping the specific growth rate (μ) and the glucose concentration (C _s) at preset values (μ _Cand C _s,c) and minimizing the ethanol production.     

Ergosterol synthesis and population Analysis of a fed-batch fermentation inSaccharomyces cerevisiae

Saccharomyces cerevisiae with an increased content of ergosterol or delta 5,7-sterols, growing on a molasses medium with a feed of ethanol and (NH4)2HPO4, was analyzed as to the age of cell population. The analysis was done by centrifugation in a dextran gradient and by a fluorescence-microscopic technique. In the phase of batch fermentation at a mean specific growth rate of 0.22 h-1 daughter cells contained less than 1% ergosterol while the ergosterol content of mother cells depended on the time of cultivation, a maximum level (4%) being found after two generation times. In the fed-batch phase at a mean growth rate of 0.052 h-1, both daughter and mother cells contained about the same amount of ergosterol (4.7-5.5%). Differences between daughter and mother cells are discussed in view of the relationship between the growth rate and the growth cycle.