Process monitoring of an industrial fed-batch fermentation

Market demand places great emphasis in industry on product quality. Consequently, process monitoring and control have become important aspects of systems engineering. In this article we detail the results of a 2-year study focusing on the development of a condition monitoring system for a fed-batch fermentation system operated by Biochemie Gmbh in Austria. We also demonstrate the suitability and limitations of current state of the art technologies in this field and suggest novel modifications and configurations to improve their suitability for application to a fed-batch fermentation system.     

Fermentation process tracking through enhanced spectral calibration modeling

The FDA process analytical technology (PAT) initiative will materialize in a significant increase in the number of installations of spectroscopic instrumentation. However, to attain the greatest benefit from the data generated, there is a need for calibration procedures that extract the maximum information content. For example, in fermentation processes, the interpretation of the resulting spectra is challenging as a consequence of the large number of wavelengths recorded, the underlying correlation structure that is evident between the wavelengths and the impact of the measurement environment. Approaches to the development of calibration models have been based on the application of partial least squares (PLS) either to the full spectral signature or to a subset of wavelengths. This paper presents a new approach to calibration modeling that combines a wavelength selection procedure, spectral window selection (SWS), where windows of wavelengths are automatically selected which are subsequently used as the basis of the calibration model. However, due to the non-uniqueness of the windows selected when the algorithm is executed repeatedly, multiple models are constructed and these are then combined using stacking thereby increasing the robustness of the final calibration model. The methodology is applied to data generated during the monitoring of broth concentrations in an industrial fermentation process from on-line near-infrared (NIR) and mid-infrared (MIR) spectrometers. It is shown that the proposed calibration modeling procedure outperforms traditional calibration procedures, as well as enabling the identification of the critical regions of the spectra with regard to the fermentation process.     

Optimization of an industrial microalgae fermentation

Optimization of cellular productivity of an industrial microalgae fermentation was investigated. The fermentation was carried out at Coors Biotech Products Company, Fort Collins, Colorado. A mathematical model was developed based on the data collected from pilot plant test runs at different operating conditions. Pontryagin's maximum principle was used for determining the optimal feed policy. A feedback control algorithm was also studied for maximizing the cellular productivity. During continuous operation, the optimum dilution rate was determined by an adaptive optimization scheme based on the steepest descent technique and a recursive least squares estimation of model parameters. A direct search algorithm was also applied to determine the optimum feed rate. Comparison of the theoretical results of the different optimization schemes revealed that the direct search algorithm was preferable because of its simplicity. The experimental results of real time application of the feedback algorithm agreed fairly well with those of the theoretical analyses. (c) 1994 John Wiley & Sons, Inc.     

Spectrofluorimetric analysis of gemifloxacin mesylate in pharmaceutical formulations

A simple, rapid and highly sensitive spectrofluorimetric method was developed for determination of gemifloxacin mesylate (GFX) in tablets. The method is based on measuring the native fluorescence of GFX in isopropanol at 400 nm after excitation at 272 nm. The fluorescence–concentration plot was rectilinear over the range of 0.01–0.50 µg/mL with a lower detection limit of 1.19 ng/mL and quantification limit of 3.6 ng/mL. The method was fully validated and successfully applied to the determination of GFX tablets with an average percentage recovery of 99.65 ± 0.532. The method was extended to the stability study of GFX. The drug was exposed to acidic, alkaline, oxidative and photolytic degradation according to International Conference on Harmonization guidelines. The rate of GFX degradation was found at its highest in acidic conditions, and in its lowest in the neutral one. However, it was stable under dry heat and photolytic degradation conditions. Copyright © 2013 John Wiley & Sons, Ltd.     

High-throughput analysis of the plasmid bioproduction process in Escherichia coli by FTIR spectroscopy

Monitoring plasmid production systems is a lab intensive task. This article proposes a methodology based on FTIR spectroscopy and the use of chemometrics for the high-throughput analysis of the plasmid bioproduction process in E. coli. For this study, five batch cultures with different initial medium compositions are designed to represent different biomass and plasmid production behavior, with the maximum plasmid and biomass concentrations varying from 11 to 95 mg L(-1) and 6.8 to 12.8 g L(-1), respectively, and the plasmid production per biomass varying from 0.4 to 5.1 mg g(-1). After a short sample processing consisting of centrifugation and dehydration, the FTIR spectra are recorded from the collected cellular biomass using microtiter plates with 96 wells. After spectral pre-processing, the predictive FTIR spectra models are derived by using partial least squares (PLS) regression with the wavenumber selection performed by a Monte-Carlo strategy. Results show that it is possible to improve the PLS models by selecting specific spectral ranges. For the plasmid model, the spectral regions between 590-1,130, 1,670-2,025, and 2,565-3,280 cm(-1) are found to be highly relevant. Whereas for the biomass, the best wavenumber selections are between 900-1,200, 1,500-1,800, and 2,850-3,200 cm(-1). The optimized PLS models show a high coefficient of determination of 0.91 and 0.89 for the plasmid and biomass concentration, respectively. Additional PLS models for the prediction of the carbon sources glucose and glycerol and the by-product acetic acid, based on metabolism-induced correlations between the nutrients and the cellular biomass are also established.     

Bio-functional legumes with nutraceutical, pharmaceutical, and industrial uses

To help or prevent certain health problems and adequately feed people, there is a need for added contributions from legumes. Legumes produce primary and secondary metabolites and other phytochemicals such as nutraceuticals, pharmaceuticals, pesticides, and industrial products. In addition, legumes such as hyacinth bean seed contain nearly 10% more fiber while winged bean contains three times more fiber than common bean. The potential breast cancer fighting chemical known as kievitone is found in hyacinth bean but not in common bean nor soybean. Both agmatine and isovitexin are potential combatants of microbial organisms in mammals including humans. Agmatine and isovitexin are not found in soybean nor common bean, however they exist in winged bean. Studies regarding value added traits such as the bio-functional and biologically active components of legumes have only recently begun because most specialty phytochemicals are extracted from other plant sources. Not only can bio-functional legumes provide healthy food constituents for use as nutraceuticals, pharmaceuticals, and pesticidals, but they can increase healthy food resources worldwide. Bio-functional legumes have been used in the past primarily for forage, pasture, minor food, green manuring, and erosion control. Current uses include these previously mentioned plus some fairly new ones such as hyacinth bean used as an ornamental and wildlife food. The future for these common bean relatives is for use in the health markets as new medicines or nutraceuticals and to provide farmers with additional crop production as phytopharmaceutical or nutraceutical crops.     

Fermentanomics: Relating quality attributes of a monoclonal antibody to cell culture process variables and raw materials using multivariate data analysis

Fermentanomics is an emerging field of research and involves understanding the underlying controlled process variables and their effect on process yield and product quality. Although major advancements have occurred in process analytics over the past two decades, accurate real‐time measurement of significant quality attributes for a biotech product during production culture is still not feasible. Researchers have used an amalgam of process models and analytical measurements for monitoring and process control during production. This article focuses on using multivariate data analysis as a tool for monitoring the internal bioreactor dynamics, the metabolic state of the cell, and interactions among them during culture. Quality attributes of the monoclonal antibody product that were monitored include glycosylation profile of the final product along with process attributes, such as viable cell density and level of antibody expression. These were related to process variables, raw materials components of the chemically defined hybridoma media, concentration of metabolites formed during the course of the culture, aeration‐related parameters, and supplemented raw materials such as glucose, methionine, threonine, tryptophan, and tyrosine. This article demonstrates the utility of multivariate data analysis for correlating the product quality attributes (especially glycosylation) to process variables and raw materials (especially amino acid supplements in cell culture media). The proposed approach can be applied for process optimization to increase product expression, improve consistency of product quality, and target the desired quality attribute profile. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1586–1599, 2015     

An assessment of seed quality and its influence on productivity estimation in an industrial antibiotic fermentation

This study investigates the benefits of including seed quality information into data-based models for final productivity estimation in an industrial antibiotic fermentation process. Multiway principal component analysis is applied to assess the seed quality using routinely gathered plant data. Multiway partial least-squares regression is then used to estimate the final productivity using data from the main fermentation only. The issue of selecting appropriate process variables as inputs is investigated. Subsequently, seed characteristics are included into the estimation models to assess the benefits of including information from this stage for productivity estimation. It is shown that it is possible to extract seed fermentation features related to the final productivity both at pilot and production scales. It is postulated that significant influential variations are mirrored in monitored variables during the main fermentation, and therefore seed quality is implicitly accounted for.     

An analysis of organism lifelines in an industrial bioreactor using Lattice-Boltzmann CFD

Euler-Lagrange CFD simulations, where the biotic phase is represented by computational particles (parcels), provide information on environmental gradients inside bioreactors from the microbial perspective. Such information is highly relevant for reactor scale-down and process optimization. One of the major challenges is the computational intensity of CFD simulations, especially when resolution of dynamics in the flowfield is required. Lattice-Boltzmann large-eddy simulations (LB-LES) form a very promising approach for simulating accurate, dynamic flowfields in stirred reactors, at strongly reduced computation times compared to finite volume approaches. In this work, the performance of LB-LES in resolving substrate gradients in large-scale bioreactors is explored, combined with the inclusion of a Lagrangian biotic phase to provide the microbial perspective. In addition, the hydrodynamic performance of the simulations is confirmed by verification of hydrodynamic characteristics (radial velocity, turbulent kinetic energy, energy dissipation) in the impeller discharge stream of a 29 cm diameter stirred tank. The results are compared with prior finite volume simulation results, both in terms of hydrodynamic and biokinetic observations, and time requirements.     

The effect of amino acid supplementation in an industrial Chinese Hamster Ovary process

The main goal in biosimilar development is to increase Chinese Hamster Ovary (CHO) viability and productivity while maintaining product quality. Despite media and feed optimization during process development, depletion of amino acids still occurs. The aim of the work was to optimize an existing industrial fed batch process by preventing shortage of amino acids and to gather knowledge about CHO metabolism. Several process outputs were evaluated such as cell metabolism, cell viability, monoclonal antibodies (mAbs) production, and product quality. First step was to develop and supplement an enriched feed containing depleted amino acids. Abundance of serine and glucose increased lactate production resulting in low viability and low productivity. In the next step, we developed an amino acid feed without serine to avoid the metabolic boost. Supplemented amino acids improved cell viability by 9%; however, mAb production did not increase significantly. In the final step, we limited glucose concentration (<5.55 mmol/L) in the cell culture to avoid the metabolic boost while supplementing an amino acid feed including serine. Data analysis showed that we were able to (a) replace depleted amino acids and avoid metabolic boost, (b) increase viability by 12%, (c) enhance mAb production by 0.5 g/L (total by approximately 10 g), and (d) extend the overall process time of an already developed bioprocess.     

发酵过程多尺度解析与调控的研究进展

工业发酵科学致力于实现高产量、高转化率和高生产强度的相对统一。通过从分子、细胞和反应器进行发酵过程多尺度解析与调控,实施全局与动态的优化与控制能够确保发酵过程高效、转化定向、过程稳定和系统有序。本文从发酵微生物代谢途径动力学模型、细胞代谢特性、发酵提取相耦合与反应器设计四个方面,总结和讨论发酵过程多尺度解析与调控的研究进展。整合分析发酵过程不同尺度特征并且针对性地开展多尺度整合调控是实现高效工业微生物发酵的重要策略。     

Revisiting flow‐chemiluminescence techniques: pharmaceutical analysis

The state of the art in flow‐chemiluminescence (flow‐CL) technique for automated pharmaceutical analysis is reviewed. Flow‐CL approaches have become powerful and promising tools for pharmaceutical screening in recent years due to their simplicity, low cost and high sensitivity. Because of these advantages, these methods have been widely used for pharmaceutical analysis in recent years. The literature reviewed covers papers of analytical interest that appeared between 2007 and mid‐2012 and have been divided into several sections based on fundamental types of CL systems employed. Furthermore, entries have been summarized alphabetically in tabular form giving details of analytical figures of merit of the methods. Copyright © 2012 John Wiley & Sons, Ltd.     

Optimization of process variables for minimization of byproduct formation during fermentation of blackstrap molasses to ethanol at industrial scale

Aims: To investigate the effect of molasses concentration, initial pH of molasses medium, and inoculum’s size to maximize ethanol and minimize methanol, fusel alcohols, acetic acid and aldehydes in the fermentation mash in industrial fermentors. Methods and Results: Initial studies to optimize temperature, nitrogen source, phosphorous source, sulfur supplement and minerals were performed. The essential nutrients were urea (2 kg in 60 m³), 0·5 l each of commercial phosphoric acid and sulfuric acid (for pH control) added at the inoculum preparation stage only. Yields of ethanol, methanol, fusel alcohols, total acids and aldehydes per 100‐l fermentation broth were monitored. Molasses at 29°Brix (degree of dissolved sugars in water), initial pH 4·5, inoculum size 30% (v/v) and anaerobic fermentation supported maximum ethanol (7·8%) with Y_P/S = 238 l ethanol per tonne molasses (96·5% yield) (8·2% increase in yield), and had significantly lower values of byproducts than those in control experiments. Conclusions: Optimization of process variables resulted in higher ethanol yield (8·2%) and reduced yield of methanol, fusel alcohols, acids and aldehydes. Significance and Impact of the Study: More than 5% substrate is converted into byproducts. Eliminating or reducing their formation can increase ethanol yield by Saccharomyces cerevisiae, decrease the overall cost of fermentation process and improve the quality of ethanol.     

Application of green analytical chemistry to a green chemistry process: Magnetic resonance and Raman spectroscopic process monitoring of continuous ethanolic fermentation

Compact ¹H NMR and Raman spectrometers were used for real-time process monitoring of alcoholic fermentation in a continuous flow reactor. Yeast cells catalyzing the sucrose conversion were immobilized in alginate beads floating in the reactor. The spectrometers proved to be robust and could be easily attached to the reaction apparatus. As environmentally friendly analysis methods, ¹H NMR and Raman spectroscopy were selected to match the resource- and energy-saving process. Analyses took only a few seconds to minutes compared to chromatographic procedures and were, therefore, suitable for real-time control realized as a feedback loop. Both compact spectrometers were successfully implemented online. Raman spectroscopy allowed for faster spectral acquisition and higher quantitative precision, NMR yielded more resolved signals thus higher specificity. By using the software Matlab for automated data loading and processing, relevant parameters such as the ethanol, glycerol, and sugar content could be easily obtained. The subsequent multivariate data analysis using partial linear least-squares regression type 2 enabled the quantitative monitoring of all reactants within a single model in real time.     

Combining mechanistic and data‐driven approaches to gain process knowledge on the control of the metabolic shift to lactate uptake in a fed‐batch CHO process

A growing body of knowledge is available on the cellular regulation of overflow metabolism in mammalian hosts of recombinant protein production. However, to develop strategies to control the regulation of overflow metabolism in cell culture processes, the effect of process parameters on metabolism has to be well understood. In this study, we investigated the effect of pH and temperature shift timing on lactate metabolism in a fed‐batch Chinese hamster ovary (CHO) process by using a Design of Experiments (DoE) approach. The metabolic switch to lactate consumption was controlled in a broad range by the proper timing of pH and temperature shifts. To extract process knowledge from the large experimental dataset, we proposed a novel methodological concept and demonstrated its usefulness with the analysis of lactate metabolism. Time‐resolved metabolic flux analysis and PLS‐R VIP were combined to assess the correlation of lactate metabolism and the activity of the major intracellular pathways. Whereas the switch to lactate uptake was mainly triggered by the decrease in the glycolytic flux, lactate uptake was correlated to TCA activity in the last days of the cultivation. These metabolic interactions were visualized on simple mechanistic plots to facilitate the interpretation of the results. Taken together, the combination of knowledge‐based mechanistic modeling and data‐driven multivariate analysis delivered valuable insights into the metabolic control of lactate production and has proven to be a powerful tool for the analysis of large metabolic datasets. © 2015 American Institute of Chemical Engineers Biotechnol. Prog., 31:1657–1668, 2015     

Rapid chemiluminometric determination of gabapentin in pharmaceutical formulations exploiting pulsed‐flow analysis

In this study, a straightforward and automated pulsed flow‐based procedure was developed for the chemiluminometric determination of gabapentin [1‐(aminomethyl)cyclo‐hexaneacetic acid], a new generation antiepileptic drug, in different formulated dosage forms. The software‐controlled time‐based injection method capitalizes on the decrease of the background chemiluminescence (CL) readout of the luminol–hypochlorite reaction in the presence of gabapentin. In short, gabapentin works as a hypochlorite scavenger. The analytical procedure was implemented in a multi‐pumping flow network furnished with a suite of microdispensing solenoid‐actuated pumps. The diaphragm‐type micropumps might be configured to operate as fluid propellers, commutation units and metering injectors. A dynamic linear working range for gabapentin concentrations in the range 60–350 µmol/L was obtained, with an estimated detection limit of 40 µmol/L. The flow analyser handles about 41 injections/h and yields precise results (RSD < 2%). The miniaturized flow analyser thus has potential to be exploited for in‐line monitoring of drug manufacturing within the quality assurance framework of modern pharmaceutical companies. Copyright © 2008 John Wiley & Sons, Ltd.     

Determination of the secondary structure of proteins in different environments by FTIR-ATR spectroscopy and PLS regression

The secondary structures of proteins (alpha-helical, beta-sheet, beta-turn, and random coil) in the solid state and when bound to polymer beads, containing immobilized phenyl and butyl ligands such as those as commonly employed in hydrophobic interaction chromatography, have been investigated using FTIR-ATR spectroscopy and partial least squares (PLS) methods. Proteins with known structural features were used as models, including 12 proteins in the solid state and 7 proteins adsorbed onto the hydrophobic surfaces. A strong PLS correlation was achieved between predictions derived from the experimental data for 4 proteins adsorbed onto the phenyl-modified beads and reference data obtained from the X-ray crystallographic structures with r(2) values of 0.9974, 0.9864, 0.9924, and 0.9743 for alpha-helical, beta-sheet, beta-turn, and random coiled structures, respectively. On the other hand, proteins adsorbed onto the butyl sorbent underwent greater secondary structural changes compared to the phenyl sorbent as evidenced from the poorer PLS r(2) values (r(2) are 0.9658, 0.9106, 0.9571, and 0.9340). The results thus indicate that the secondary structures for these proteins were more affected by the butyl sorbent, whereas the secondary structure remains relatively unchanged for the proteins adsorbed onto the phenyl sorbent. This study has important ramifications for understanding the nature of protein secondary structural changes following adsorption onto hydrophobic sorbent surfaces. This knowledge could also enable the development of useful protocols for enhancing the chromatographic purification of proteins in their native bioactive states. (c) 2008 Wiley Periodicals, Inc. Biopolymers 89: 895-905, 2008.This article was originally published online as an accepted preprint. The "Published Online" date corresponds to the preprint version. You can request a copy of the preprint by emailing the Biopolymers editorial office at biopolymers@wiley.com.