Fermentation broth rheology during dextran production by Leuconostoc mesenteroides B512(F) as a possible tool for control

Dextran is a polysaccharide produced commercially by Leuconostoc mesenteroides B512(F) growing on excess sucrose. The high viscosity of the resulting broth makes process analysis and control extremely difficult. In an attempt to overcome this the broth rheology was monitored with time and correlated with other process variables. It was determined that the viscosity and pseudo-plasticity increase through most of the fermentation, but then go through a sharp maximum immediately prior to completion of dextran synthesis and sucrose consumption. This was attributed to release of dextran molecules from the cell wall, reducing the size of polymer aggregates in solution. As such, the change in rheology provides a marker for the completion of the fermentation. The analysis requires no pretreatment of the broth, and it is envisaged that an on-line viscometer, determining apparent broth viscosity at a single shear rate, could be used for process monitoring and control. This would enable early detection of operating upsets, as well as avoid errors introduced by manual sampling and analysis, ans permit the optimum point at which to harvest the broth to be selected more precisely. Correspondence to: C. Webb     

A quartz crystal viscosity sensor for monitoring coagulation reaction and its application to a multichannel coagulation detector

A quartz crystal viscosity sensor was applied to a coagulation reaction monitoring system. The system consists of 16 oscillating circuits, a channel selector, a frequency counter, a temperature controller and a microcomputer. The system is named the Quartz Chemical Analyzer (QCA). AT-cut quartz crystals (9 MHz) were used as viscosity detectors and were attached to a cell in order to expose only one side of the quartz plate. The system was applied to the detection of the blood coagulation factors VIII (F VIII) and IX (F IX). The activity of these factors was assayed by a single-stage method. A linear relationship was obtained in a double-logarithmic diagram of concentration versus coagulation time with respect to F VIII and F IX in the range 0.05-0.4 unit cm-3 and 0.025-0.2 unit cm-3, respectively.     

Impedance characterization of a piezoelectric immunosensor part II: Salmonella typhimurium detection using magnetic enhancement

This study investigated the usefulness and characteristics of a 5-MHz quartz crystal resonator as a sensor of biological pathogens such as Salmonella typhimurium. An impedance analyzer measured the impedance behavior of the oscillating quartz crystal exposed to various concentrations of Salmonella (10(2)-10(8) cells per ml). The Salmonella cells were captured by antibody-coated paramagnetic microspheres, and then these complexes were moved magnetically to the sensing quartz and were captured by antibodies immobilized on the crystal surface. The response of the crystal was expressed in terms of equivalent circuit parameters. The motional inductance and the motional resistance increased as a function of the concentration of Salmonella. The viscous damping was the main contributor to the resistance and the inductance in a liquid environment. The load resistance was the most effective and sensitive circuit parameter. A magnetic force was a useful method to collect the complexes of Salmonella-microspheres on the crystal surface and enhance the response of the sensor. In this system, the detection limit, based on resistance monitoring, was about 10(3) cells per ml.     

Detecting cell lysis using viscosity monitoring in E. coli fermentation to prevent product loss

Monitoring the physical or chemical properties of cell broths to infer cell status is often challenging due to the complex nature of the broth. Key factors indicative of cell status include cell density, cell viability, product leakage, and DNA release to the fermentation broth. The rapid and accurate prediction of cell status for hosts with intracellular protein products can minimise product loss due to leakage at the onset of cell lysis in fermentation. This article reports the rheological examination of an industrially relevant E. coli fermentation producing antibody fragments (Fab'). Viscosity monitoring showed an increase in viscosity during the exponential phase in relation to the cell density increase, a relatively flat profile in the stationary phase, followed by a rapid increase which correlated well with product loss, DNA release and loss of cell viability. This phenomenon was observed over several fermentations that a 25% increase in broth viscosity (using induction‐point viscosity as a reference) indicated 10% product loss. Our results suggest that viscosity can accurately detect cell lysis and product leakage in postinduction cell cultures, and can identify cell lysis earlier than several other common fermentation monitoring techniques. This work demonstrates the utility of rapidly monitoring the physical properties of fermentation broths, and that viscosity monitoring has the potential to be a tool for process development to determine the optimal harvest time and minimise product loss. © 2016 The Authors. Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers, 32:1069–1076, 2016     

Gas chromatography and gateway sensors for on-line state estimation of complex fermentations (butanol-acetone fermentation)

A fermentation system has been designed to demonstrate the use of gas chromatography (GC) for on-line monitoring of the butanol-acetone and other complex saccharolytic fermentations. Tangential flow ultrafiltration was used to sterilely and continuously obtain a cell-free filtrate from the fermentation broth for on-line GC analysis of butanol, butyrate, acetate, acetone, ethanol, and acetoin. The liquid injection system consists of a phosphoric acid contactor, a slider-type injection valve, and a heater to address the difficulties (ghosting) encountered in the analysis of carboxylic acids. The fermentation headspace gas was also analyzed by on-line GC for nitrogen and carbon dioxide, while hydrogen was measured by difference. Raw chromatographic data were analyzed by a chromatography data system. Both raw and processed data were transmitted to a VAX 11/750 computer for further processing (using the fermentation equation) and archiving. The fermentation equation, which has recently been derived and tested on completed fermentation data, was also found to be valid during transient fermentations and thus useful as a gateway sensor for calculating various fermentation parameters on-line. Such parameters include glucose concentration and gas composition, as well as a number of unobservable parameters (such as Y(ATP), excess ATP, and NAD reduced by FdH(2)), which characterize the state of the fermentation.     

New instrument for on-line viscosity measurement of fermentation media

In an attempt to resolve the difficult problem of on-line determination of the viscosity of non-Newtonian fermentation media, the authors have used a vibrating rod sensor mounted on a bioreactor. The sensor signal decreases nonlinearly with increased apparent viscosity. Electronic filtering of the signal damps the interfering effect of aeration and mechanical agitation. Sensor drift is very low (0.03% of measured value per hour).On the rheological level the sensor is primarily an empirical tool that must be specifically calibarated for each fermentation process. Once this is accomplished, it becomes possible to establish linear or second-degree correlations between the electrical signal from the sensor and the essential parameters of the ferementation process in question (pH of a feremented milk during acidification, concentration of extra cellular polysaccharide). In addition, by applying the power law to describe the rheological behavior of fermentation media, we observe a second-order polynomial correlation between the sensor signal and the behavior index (n).     

Polysaccharide concentration and molecular weight effects on the oxygen mass transfer in a reciprocating plate bioreactor

In most polysaccharide fermentations, the nature of the fermentation broth changes drastically with time and, as a result, the overall oxygen mass transfer coefficient (K(L)a) can vary by orders of magnitude. To obtain a better understanding of this phenomenon, an experimental program was devised to study the respective influence of molecular weight and concentration of dextran solutions on K(L)a. Experiments were conducted in a reciprocating plate bioreactor. This bioreactor uses a stack of perforated plates that is reciprocated axially in the column and it is therefore well suited for mixing viscous liquid broths and providing uniform overall mass transfer coefficients. The variation of K(L)a with the power input per unit volume and the superficial gas velocity were obtained for three ranges of molecular weights and five concentrations of dextran. In every medium, two regimes of operation were observed as a function of the power input per unit volume: a first regime, at low power inputs per unit volume where K(L)a remains constant until a threshold of power input is attained; and a second regime, which is characterized by a steep increase of K(L)a as a function of the power input per unit volume. The presence of dissolved biological macromolecules, not only because of their effect on the rheology of the medium but also because their effect on the gas-liquid interface, has a significant impact on K(L)a. It was found that, generally, small concentrations of polysaccharide favor oxygen mass transfer despite the increase in medium viscosity. However, the respective influence of polysaccharide concentration and molecular weight was different for the two regimes of operation. (c) 1996 John Wiley & Sons, Inc.     

Use of fluorometry for monitoring and control of a bioreactor

A new fluorescent bioreactor monitoring probe-multiple excitation fluorometric system (MEFS)-has been developed. This probe was compared to the commercially available BioChem Technology FluroMeasure system (NADH probe). In this task the fluorescence behavior of three model fermentation systems, ethanol fermentation by Candida utilis, phenol fermentation by Pseudomonas putida, and glucose fermentation by Saccharomyces cerevisiae, were examined. The results indicated that the fluorescence intensity and behavior of various cellular fluorophors vary significantly between the different fermentation systems. Monitoring a fermentation process using only NAD(P)H fluorescence provided limited information. The NAD(P)H fluorescence was found not to be the best fluorescence signal for monitoring cell concentrations. The best way of monitoring a bioreactor by fluorometry may be to monitor several fluorophors in the whole culture broth simultaneously and to relate these fluorescence signals to various biological parameters.     

Combined dissolved oxygen tension and online viscosity measurements in shake flask cultivations via infrared fluorescent oxygen-sensitive nanoparticles

Oxygen supply is one of the most critical process parameters in aerobic cultivations. To assure sufficient oxygen supply, shake flasks are usually used in combination with orbital shaking machines. In this study, a measurement technique for the dissolved oxygen tension (DOT) in shake flask cultures with viscosity changes is presented. The movement of the shaker table is monitored by means of a Hall effect sensor. For DOT measurements, infrared fluorescent oxygen-sensitive nanoparticles are added to the culture broth. The position of the rotating bulk liquid needs to be determined to assure measurements inside the liquid. The leading edge of the bulk liquid is detected based on the fluorescence signal intensity of the oxygen-sensitive nanoparticles. Furthermore, online information about the viscosity of the culture broth is acquired due to the detection of the position of the leading edge of the bulk liquid relative to the direction of the centrifugal force, as described by Sieben et al. (2019. Sci. Rep., 9, 8335). The DOT measurement is combined with a respiration activity monitoring system which allows for the determination of the oxygen transfer rate (OTR) in eight parallel shake flasks. Based on DOT and OTR, the volumetric oxygen transfer coefficient (k_La) is calculated during cultivation. The new system was successfully applied in cultivations of Escherichia coli, Bacillus licheniformis, and Xanthomonas campestris.     

Detection of Pseudomonas aeruginosa using a wireless magnetoelastic sensing device

This paper describes the real-time quantification of Pseudomonas aeruginosa (P. aeru) concentrations using a wireless magnetoelastic sensing device. The sensor is fabricated by coating a magnetoelastic ribbon with a polyurethane protecting film. In response to an externally applied time varying magnetic field, the magnetoelastic sensor vibrates at a resonance frequency that can be remotely determined by monitoring the magnetic flux emitted by the sensor. The resonance frequency changes in response to properties changes of a liquid culture medium and bacteria adhesion to the sensor as P. aeru consumes nutrients from the culture medium in growth and reproduction. The effects of properties (conductivity, viscosity, mass) are investigated with quartz crystal microbalance (QCM), microscopy imaging, and conductivity measurement. Using the described technique we are able to directly quantify P. aeru concentrations of 10(3) to 10(8)cells/ml, with a detection limit of 10(3)cells/ml at a noise level of approximately 20 Hz. The lack of any physical connections between the sensor and the monitoring electronics facilitates aseptic operation, and makes the sensor platform ideally suited for monitoring bacteria from within, for example, sealed food containers.     

Sensing performance of protein C immuno-biosensor for biological samples and sensor minimization

Protein C (PC) is an important anticoagulant and antithrombotic agent in human blood plasma. PC deficiency can result in clotting complications that interfere with oxygen and nutrient transport. A fiber-optic biosensor is being developed to provide real time diagnosis of PC deficiency. The PC sensor was tested to quantify PC level in human plasma. The signal intensity obtained from the plasma sample was 30% of the buffered sample, possibly due to the increased viscosity. The feasibility of monitoring PC level in animal cell culture broth and animal milk was tested. For the cell culture broth, 80% of signal was observed. However, the decrease was consistent over the sensing range. For whole and 1:100 diluted bovine milk, the signals were 60 and 78% of buffered sample, respectively. The biosensor length was reduced from 12.5 to 6 cm with sufficient sensitivity. To increase the sensor reusability, various elution buffers were applied after each sensing. Triethylamine elution buffer provided the best sensor regeneration capability and increased the number of assays from 2.5 to 7 times for 6 cm fibers.     

On-line rheological measurements and control in fungal fermentations

A system for on-line rheological measurements and control in filamentous fermentations is presented. The output signals from the control unit can be used in terms of process control. Diluting the broth in a growth controlled feed pattern was found to influence the viscosity of the broth and lead to process improvements. Just diluting the fermentation broth to keep the viscosity below a preset value was seen to give only temporary process improvements. The higher the viscosity, the less effective the viscosity controlled dilutions. The failure to get full control over the viscosity by the dilution techniques used is caused by the large number of factors influencing the rheological properties of an Aspergillus niger culture. The factors shown in this work to influence the rheological properties of the fermentation broth were the biomass concentration, the specific growth rate, mixing qualities (impeller speed and working volume), and the dissolved oxygen concentration. (c) 1992 John Wiley & Sons, Inc.     

Calibration of the viscometric glucose sensor before its use in physiological liquids--compensation for the colloid-osmotic effect

The function of the recently described viscometric affinity sensor (VAS), which measures glucose due to its strong effect on the viscosity of a sensitive liquid containing Concanavalin A (ConA) and dextran, was analysed for osmotic and colloid-osmotic effects on the glucose reading. The suction of low- and high-molecular weight osmotica on the membrane of the microdialysis fibre was measured using a membrane osmometer built from the microdialysis probe of the VAS. The reduction of the sensor read-out in blood plasma can be completely explained by a change in small osmotic volume fluxes through the dialysis membrane, which affect the ConA concentration and the viscosity after the flow of the sensitive liquid through the dialysis probe. The measuring error could be prevented by the presence of the polyethylene glycol 6000 at an isotonic concentration in the glucose standard solutions used for sensor calibration.     

Application of parylene-coated quartz crystal microbalance for on-line real-time detection of microbial populations

A novel technique of applying a quartz crystal microbalance (QCM) sensor to the on-line real-time detection of microbial populations is described. The pQCM sensor was fabricated by depositing di-para-xylene (parylene) over the entire surface of a QCM sensor through a chemical vapor deposition (CVD) process. An electrically insulated film of parylene on the QCM sensor enabled the operation of the sensor in the liquid environment, and the resonance frequency of the pQCM sensor set in the medium of a cultivation flask shifted in response to the microbial population. The effects of pH, conductivity, and viscosity of the medium on the frequency shift of the pQCM sensor were investigated. Ignorable responses (less than 1% at 10(3)cells) were obtained during an incubation cycle. The detection limit of the pQCM sensor was identified as 10(2) cells ml(-1) with a frequency shift of around 2 x 10(3)Hz. The cell numbers of Escherichia coli cultivated in both the YEM medium and whole milk were detected. A satisfactory correlation (r(2)=0.95) was obtained between the cell number and the response of the pQCM sensor. Experimental results suggest that the pQCM described here is applicable to the continuous long-term detection of microbial populations during a fermentation process.     

Extractive acidogenic fermentation by a supported liquid membrane

An on-line extractive fermentation system using a supported liquid membrane, recently termed pertractive fermentation, was investigated in order to overcome end-product inhibition and to enhance the productivity of microbial acidogenesis. It was observed that the pH of the fermentation broth was the key parameter for the successful operation of this pertractive fermentation system. At pH 4.8, 300 ml of broth and 80 sq·cm of extracting area, microbial activity in the system was prolonged and the productivity was enhanced about 5 fold compared to conventional acidogenic fermentation without extraction.     

On-line monitoring and controlling system for fermentation processes

A personal computer-based on-line monitoring and controlling system was developed for the fermentation of microorganism. The on-line HPLC system for the analysis of glucose and ethanol in the fermentation broth was connected to the fermenter via an auto-sampling equipment, which could perform the pipetting, filtration and dilution of the sample and final injection onto the HPLC through automation based on a programmed procedure. The A/D and D/A interfaces were equipped in order to process the signals from electrodes and from the detector of HPLC, and to direct the feed pumps, the motor of stirrer and gas flow-rate controller. The software that supervised the control of the stirring speed, gas flow-rate, pH value, feed flow-rate of medium, and the on-line measurement of glucose and ethanol concentration was programmed by using Microsoft Visual Basic under Microsoft Windows. The signal for chromatographic peaks from on-line HPLC was well captured and processed using an RC filter and a smoothing algorithm. This monitoring and control system was demonstrated to be effective in the ethanol fermentation of Zymomonas mobilis operated in both batch and fed-batch modes. In addition to substrate and product concentrations determined by on-line HPLC, the biomass concentration in Z. mobilis fermentation could also be on-line estimated by using the pH control and an implemented software sensor. The substrate concentration profile in the fed-back fermentation followed well the set point profile due to the fed-back action of feed flow-rate control.     

Simultaneous solid–liquid separation and primary purification of clavulanic acid from fermentation broth of Streptomyces clavuligerus using salting‐out extraction system

Clavulanic acid (CA) is usually used together with other β‐lactam antibiotics as combination drugs to inhibit bacterial β‐lactamases, which is mainly produced from the fermentation of microorganism such as Streptomyces clavuligerus. Recently, it is still a challenge for downstream processing of low concentration and unstable CA from fermentation broth with high solid content, high viscosity, and small cell size. In this study, an integrated process was developed for simultaneous solid–liquid separation and primary purification of CA from real fermentation broth of S. clavuligerus using salting‐out extraction system (SOES). First, different SOESs were investigated, and a suitable SOES composed of ethanol/phosphate was chosen and further optimized using the pretreated fermentation broth. Then, the optimal system composed of 20% ethanol/15% K₂HPO₄ and 10% KH₂PO₄ w/w was used to direct separation of CA from untreated fermentation broth. The result showed that the partition coefficient (K) and recovery yield (Y) of CA from untreated fermentation broth were 29.13 and 96.8%, respectively. Simultaneously, the removal rates of the cells and proteins were 99.8% and 63.3%, respectively. Compared with the traditional method of membrane filtration or liquid–liquid extraction system, this developed SOES showed the advantages of simple operation, shorter operation time, lower process cost and higher recovery yield of CA. These results demonstrated that the developed SOES could be used as an attractive alternative for the downstream processing of CA from real fermentation broth.     

Effect of cycle time on fungal morphology, broth rheology, and recombinant enzyme productivity during pulsed addition of limiting carbon source

For many years, high broth viscosity has remained a key challenge in large-scale filamentous fungal fermentations. In previous studies, we showed that broth viscosity could be reduced by pulsed addition of limiting carbon during fed-batch fermentation. The objective in this study was to determine how changing the frequency of pulsed substrate addition affects fungal morphology, broth rheology, and recombinant enzyme productivity. To accomplish this, a series of duplicate fed-batch fermentations were performed in 20-L fermentors with a recombinant glucoamylase producing strain of Aspergillus oryzae. The total cycle time for substrate pulsing was varied over a wide range (30-2,700 s), with substrate added only during the first 30% of each cycle. As a control, a fermentation was conducted with continuous substrate feeding, and in all fermentations the same total amount of substrate was added. Results show that the total biomass concentration remained relatively unaltered, while a substantial decrease in the mean projected area of fungal elements (i.e., average size) was observed with increasing cycle time. This led to reduced broth viscosity and increased oxygen uptake rate. However, high values of cycle time (i.e., 900-2,700 s) showed a significant increase in fungal conidia formation and significantly reduced recombinant enzyme productivity, suggesting that the fungi channeled substrate to storage compounds rather than to recombinant protein. In addition to explaining the effect of cycle time on fermentation performance, these results may aid in explaining the discrepancies observed on scale-up to larger fermentors.     

A simple capillary viscosity meter for the on-line measurement and control of the biomass concentration in high-density cultures

A capillary viscosity meter was used for the on-line determination of the biomass concentration in a fermentation broth. At high cell densities the viscosity of the broth increases, which can be measured as the pressure drop over a capillary. Calibration aspects of this viscosity meter are presented, and the use of the device for the control of the biomass concentration in a membrane recycle fermentor is demonstrated.     

Series quartz crystal sensor for remote bacteria population monitoring in raw milk via the Internet

A remote monitoring system based on a piezoelectric quartz crystal (SPQC) sensor was developed for the determination of the bacteria population in raw milk. The system employs the Windows XP server operating system, and its programs for data acquisition, display and transmission were developed using the LabVIEW 7.1 programming language. The circuit design consists of a circuit with a piezoelectric quartz crystal (SPQC) and a pair of electrodes. This system can provide dynamic data monitoring on a web-page via the Internet. Immersion of the electrodes in a cell culture with bacteria inoculums resulted in a change of frequency caused by the impedance change due to microbial metabolism and the adherence of bacteria on the surface of the electrodes. The calibration curve of detection times against density of bacteria showed a linear correlation coefficient (R(2) = 0.9165) over the range of 70-10(6) CFU ml(-1). The sensor could acquire sufficient data rapidly (within 4 h) and thus enabled real-time monitoring of bacteria growth via the Internet. This system has potential application in the detection of bacteria concentration of milk at dairy farms.