Corrosion in bioprocessing applications

Corrosion in bioprocessing applications is described for a 25-year-old bioprocessing pilot plant facility. Various available stainless steel alloys differ greatly in properties owing to the impact of specific alloying elements and their concentrations. The alloy property evaluated was corrosion resistance as a function of composition under typical bioprocessing conditions such as sterilization, fermentation, and cleaning. Several non-uniform forms of corrosion relevant to bioprocessing applications (e.g., pitting, crevice corrosion, intergranular attack) were investigated for their typical causes and effects, as well as alloy susceptibility. Next, the corrosion resistance of various alloys to specific bioprocessing-relevant sources of corrosion (e.g., medium components, acids/bases used for pH adjustment, organic acid by-products) was evaluated, along with the impact of temperature on corrosion progression. Best practices to minimize corrosion included considerations for fabrication (e.g., welding, heat treatments) and operational (e.g., sterilization, media component selection, cleaning) approaches. Assessments and repair strategies for observed corrosion events were developed and implemented, resulting in improved vessel and overall facility longevity.     

Effect of aeration conditions on the biosynthesis of carminomycin by an actinomadura carminata culture]

The effect of the aeration rate on biosynthesis of carminomycin by Actinomadura carminata and biochemical changes in the fermentation broth on the use of 3 complex media of different composition was studied. The carminomycin-producing organism can grow and produce the antibiotic within the ranges of the aeration changes from 0.98 to 18.56 mgO2/1-min. A decrease in the maximum rate of oxygen dissolution up to 0.98 mgO2/1-min resulted in some decrease in the activity level. Intensive aeration, i.e. 18.56 mgO2/1-min induced suppression of the antibiotic production by 25 per cent.     

Complete design analysis of a continuous sterilizer for fermentation media containing suspended solids

An improved mathematical model was developed to design a continuous sterilizer for liquid fermentation media containing suspended solids. Unsteady-state energy balances were used to determine the temperature distribution in the liquid medium and in the solid particles as a function of time and position within the particle, as the medium flows through the sterilizer. Such temperature profiles were used to determine the level of microbial reduction achieved by each component of the sterilizer and by the entire sterilization process. A considerable difference exists between the temperature in the particle core and in the surrounding liquid. This has a significant impact on the degree of sterility achieved by the process. The level of microbial reduction in the particles was found to be tens and or even hundreds of order of magnitude lower than the corresponding level achieved in the liquid. The role of the particle material on the degree of sterilization was also investigated. Solid materials typically found in fermentation media, such as wood or flour clumps were found to offer considerable resistance to the sterilization of the organisms lodged inside them. (c) 1993 Wiley & Sons, Inc.     

Effect of the Composition of Culture Media on the Laccase Production of Lentinus edodes Strains

The effect of charge, ion radii and concentration of cations and fermentation time on the laccase production of four Lentinus edodes strains was determined using 28 different fermentation media and 60 days of fermentation time. Samples were taken every 10 days and the laccase activity was determined by visible spectrophotometry. Principal component analysis (PCA) was used for the assessment of similarities and dissimilarities between the laccase activities of the samples. As PCA is not suitable for the separation of the strength (potency) and selectivity of the effect of various factors (composition of cultures, fermentation ime, Lentinus edodes strains) on the laccase production, they were separated by the spectral mapping technique (SPM). The dimensionality of the matrices of PC loadings and variables and the selectivity maps were reduced to two by the non‐linear mapping technique. The results of PCA and SPM were compared by calculating linear relationships among the potency values and the corresponding coordinates of PCA and SPM maps. It was established that neither the type of the cations nor their concentration in the fermentation media had a significant effect on the laccase production. It was found that the type of the Lentinus edodes strains and the fermentation time exerts a considerable effect both on the strength and on the selectivity of the laccase production. It was further proven that the results of PCA and SPM were considerably different. Therefore, their simultaneous application in future quantitative structure activity relationship (QSAR) studies is highly recommended.     

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

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

Criteria for evaluating calcium carbonate from the point of view of chlortetracycline biosynthesis]

Calcium carbonate is added to fermentation media in biosynthesis of tetracyclines for providing definite pH values and binding tetracycline into insoluble complexes. Seven different samples were studied with respect to their physical properties, such as the microscopic size of the particles, their form, capacity for agglomeration, specific volume, rate of the particle precipitation and chemical properties, such as purity, buffer capacity, effect on the medium pH before and after sterilization. The above properties were studied in comparison with activity chlortetracycline biosynthesis. Microfine calcium carbonate proved to be the best from the point of view of productivity of Str. aureofaciens. With its use the activity of the culture fluid increased by 20 per cent as compared to the other samples. The titration curve of the sample had the lowest bend.     

Investigation of the effects of oxidative stress-inducing factors on culturing and productivity of Bordetella pertussis

The stress response of Bordetella pertussis during fermentation was assessed by means of fluorescence-based techniques. During the manufacturing of vaccines, B. pertussis is subjected to stress during adaptation to a new environment and operating conditions in the bioreactor, which can have harmful consequences on growth and protein yield. In this study, stress was imposed by varying the percentage of dissolved oxygen (DO) and inoculum size, and by adding rotenone and hydrogen peroxide. In this study, fluorescence spectroscopy is used as a tool for measuring oxidative stress. High levels of DO during fed-batch operation had no detrimental effect on growth, but the specific productivity of pertactin (PRN) decreased. Cultures that were started with an inoculum size that was 10 times smaller than the control resulted in significantly less PRN as compared to controls where reduction was more significant in flasks as compared to bioreactors. A comparison of filtered to heat-sterilized media revealed that filtered media offered a protective effect against H₂O₂. Heat sterilization of the media might result in the destruction of components that offer protection against oxidative stress. Nonetheless, filter sterilization on its own would be insufficient for large-scale manufacturing. It should be emphasized that the effects of these stressors while investigating for other microorganisms have not been studied for B. pertussis.     

Fehlermöglichkeiten der Gelöstsauerstoffmessung beim Betrieb von Bioreaktoren

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

Enzyme Production of Pleurotus ostreatus Evaluated by the Three‐Way Principal Component Analysis

The effect of the composition of culture media and fermentation time on the production of β‐glucosidase, xylanase, laccase, manganese‐dependent and independent peroxidases by the edible fungus Pleurotus ostreatus was determined. Culture medium separately containing potato, pepper, and tomato extracts and the enzyme activities were assessed to 31.5 days of fermentation. Three‐dimensional principal component analysis (3D‐PCA) followed by the plots of the first two elements of component matrices was employed for the elucidation of the similarities and dissimilarities between the parameters. It was established that the dimensionality of the original 3D matrix (9, 5, 4) could be reduced to 2, 1, 2 with 4.54 % loss of information. The plots demonstrated that the culture media displayed large differences in their capacity to promote enzyme production and that the presence of pepper and tomato extracts exerted the greatest influence on the enzyme activities. The effect of the fermentation time was manifested only after 14 d of fermentation and the highest differences were observed after 28 and 31.5 d of fermentation. Except laccase and manganese‐dependent peroxidase, the enzyme activities also differed considerably dependent on the composition of the fermentation broth. 3D‐PCA followed by the plots of component matrices is a valuable tool for the simultaneous assessment of three dimensional data matrices in biotechnological processes.     

Sterilization of bioreactor media on the basis of computer calculated thermal input designated asF 0

Summary Industrial fermentation media are normally sterilized with steam to destroy the indigenous microbial population prior to inoculation with a specific microorganism. Because biological validation of each sterilization cycle is impractical, an overkill approach is commonly employed on the basis that alteration of heat-sensitive nutrients is less detrimental than survival of indigenous microbes. However, the heat destruction of microbes is known to be a probability function amenable to calculation. A computer has been programmed to calculate the on-line heat input asF ₀ values during sterilization of media in stirred bioreactors. The accumulation ofF ₀ values is then announced verbally to bioreactor operators by a communications controller with voice synthesizer.     

Treating cell culture media with UV irradiation against adventitious agents: Minimal impact on CHO performance

Sterility of cell culture media is an important concern in biotherapeutic processing. In large scale biotherapeutic production, a unit contamination of cell culture media can have costly effects. Ultraviolet (UV) irradiation is a sterilization method effective against bacteria and viruses while being non‐thermal and non‐adulterating in its mechanism of action. This makes UV irradiation attractive for use in sterilization of cell culture media. The objective of this study was to evaluate the effect of UV irradiation of cell culture media in terms of chemical composition and the ability to grow cell cultures in the treated media. The results showed that UV irradiation of commercial cell culture media at relevant disinfection doses impacted the chemical composition of the media with respect to several carboxylic acids, and to a minimal extent, amino acids. The cumulative effect of these changes, however, did not negatively influence the ability to culture Chinese Hamster Ovary cells, as evaluated by cell viability, growth rate, and protein titer measurements in simple batch growth compared with the same cells cultured in control media exposed to visible light. © 2014 American Institute of Chemical Engineers Biotechnol. Prog., 30:1190–1195, 2014     

Effect of Method of Agar Addition on Post-autoclave pH of the Tissue Culture Media

Tissue culture media (MS, GB-5 and N6) were gelled with agarby employing different methods When agar was dissolved directlyin media by autoclaving at 120 °C for 1 mm followed by sterilization,the media pH dropped markedly — more so at the lower concentrationsof agar On the other hand, when agar was first dissolved indistilled water and added to the culture media the pH loss wasminimized considerably pH measurements carried out as a functionof time showed a gradual decline in media pH The media supplementedwith Panax ginseng callus became more acidic than the mediawith no callus Tentative reasons for the post autoclave pH fallassociated with various methods of agar addition are described Culture media, agar addition, post-autoclave pH, Panax gingseng     

Influence of antimicrobial agents on contamination and chlortetracycline production

The possibility of shortening the thermal sterilization time for cultivating media was demonstrated in chlortetracycline fermentation with an industrial strain ofStreptomyces aureofaciens. The medium was artificially contaminated with a mixture of eight strains of G + and G-bacteria isolated from contaminated industrial fermentors, and the following chemical agents, either alone or in combination, were added: formaldehyde, phenol, dimethylformamide,p-aminosalicylic acid and nitrofurazone. Dimethylformamide was inhibitory even at 0.08%. formaldehyde concentrations higher than 0.05%, Nitrofurazone stimulated chlortetracycline production, The best combination was 0.01% formaldehyde added before, and 2.10^-3% nitrofurazone added after short sterilization at 120 °C.     

Beneficial effect of protracted sterilization of lentils on phytase production by Aspergillus ficuum in solid state fermentation

Water addition to the solid substrate preceding autoclaving increased substrate porosity and phytase production in solid state fermentation. In comparison with dry sterilization, the phytase activity increased 6‐, 8.5‐, and 10‐fold when the autoclaving time was 20, 40, and 60 min, respectively. Autoclaving increased the void space of sterilized lentils, and the increase was 16% higher when water was supplemented to the lentils before sterilization. Image analysis of SEM pictures of the solid substrate showed that water supplementation presterilization portended greater micro‐fissure surface area, which also increased with increasing the sterilization time. SEM pictures of the fermentation product showed that fungal growth into the center of the solid substrate was ubiquitous when water was supplemented before sterilization but was absent when water was supplemented post sterilization. Similarly, spore formation on the substrate surface for the presterilization water supplementation samples far exceeded spore formation for samples that received supplementation poststerilization. This evidence suggests that improved mass transfer into the solid substrate resulting from additional pore volume and the formation of micro‐fissures on the substrate surface is responsible for the observed gains in phytase productivity in solid state fermentation. © 2012 American Institute of Chemical Engineers Biotechnol. Prog., 2012     

重组人碱性成纤维细胞生长因子工程菌的发酵工艺研究

对大肠杆菌表达的rh-bFGF工程菌的发酵条件进行了研究,探讨了发酵条件对工程菌表达外源蛋白量及细菌收率的影响,优化了影响发酵的各种条件,如培养基配方,pH值,补料,诱导表达时机等,形成了一套工程菌发酵表达外源蛋白成熟工艺,并从工业化角度对工程菌的高密度,高表达间的关系进行了探讨。     

Simultaneous measurements of oxygen diffusion coefficients and solubilities in fermentation media with polarographic oxygen electrodes

A membrane-covered oxygen electrode was used to measure oxygen diffusion coefficients and solubilities in aqueous glucose solutions and various fermentation media following a newly developed methodology. The fermentation media studied were tryptic soy broth and those for fermentations of Penicillium chrysogenum, Saccharomyces cerevisiae, and Micrococcus glutamicus. The experimental results of oxygen diffusion coefficients and solubilities in glucose solutions were in good accord with the literature data. As for the fermentation media, both oxygen diffusion coefficients and solubilities were found to decrease with an increased fractional composition of these media, and log-additive behaviors of the oxygen diffusion coefficients and solubilities in fermentation media were observed.     

接种固定化粪菌和培养基种类对体外结肠菌群发酵的影响

目的研究三种模拟结肠发酵培养基和粪菌固定化对体外结肠发酵体系菌群构成的影响,为建立高度模拟结肠体外结肠发酵提供参考。方法采集健康女性成人粪便,粪便制备悬液或用结冷胶-黄原胶固定化粪菌接种于模拟结肠发酵反应器,分别用三种培养基按0.07 m L/h稀释率进行连续发酵10 d,用末端限制性片段长度多态性(T-RFLP)与高通量测序技术分析菌群多样性,并分析发酵液短链脂肪酸含量。结果 T-RFLP分析显示,培养基类型主要影响粪菌固定体系菌群α多样性达到稳定的时间和多样性。β多样性分析显示,第10天时培养基Ⅲ悬液培养和培养基I固定化培养系统的菌群构成与粪便菌群最相近。而培养基Ⅲ在第10天达到较高而稳定的丁酸浓度。结论由于比粪菌固定培养更易操作,培养基Ⅲ悬液培养适于模拟人结肠发酵。     

Effects of yeast proteolytic activity on Oenococcus oeni and malolactic fermentation

Alcoholic fermentation of synthetic must was performed using either Saccharomyces cerevisiae or a mutant Deltapep4, which is deleted for the proteinase A gene. Fermentation with the mutant Deltapep4 resulted in 61% lower levels of free amino acids, and in 62% lower peptide concentrations at the end of alcoholic fermentation than in the control. Qualitative differences in amino acid composition were observed. Changes observed in amino acids in peptides were mainly quantitative. After alcoholic fermentation, each medium was inoculated with Oenococcus oeni. Malolactic fermentation in the medium with the Deltapep4 strain took 10 days longer than the control. This difference may have been due to a difference in the nitrogen composition of the two media. Free amino acids and amino acids in peptides were poorly consumed by O. oeni. Thus, the qualitative aspects of nitrogen composition, which depend in part on yeast metabolism, may be a determinant for the optimal growth of O. oeni in wine.     

金霉菌的生理与金霉素的生产 I.接种培养基对于金霉菌的代谢及抗生素产量的影响

将金莓菌的芽孢接种到不同的接种培养基中,24小时后再接种到同一的酦酵培养基上,发现金霉素的产量有显著不同。一个好的接种培养基比一个坏的接种培养基所生的菌体在酦酵过程中产生的金霉素可以大出7至8倍。接种培养基的 pH 值对于以后菌体在酦酵培养基中金霉素的生产也有显著的影响。接种培养基并不显著地影响菌体在酦酵培养基上的生长,但已显然变更了它的代谢作用。由不同接种培养基中萌生的菌体,在同一酦酵培养基中醣的利用率不同,氧化的能力不同,有机酸的形成和堆积也不同,它们对于一些金属元素的反应也不一样。这个研究证明了金霉菌的初期的培养环境,对于以后菌体的发育和金霉素的生产有极大的影响。同时亦指出了金霉菌的发育在不同时期需要不同的环境,有着不同的代谢类型。去掌握这个生物规律——环境条件和发育的过程,是正确的研究方向,是提高抗生素产量的必要途径。     

Using spectrophotometry and spectral mapping technique for the study of the production of manganese-dependent and manganese-independent peroxidases by Pleurotus ostreatus

The activity of manganese-dependent and manganese-independent peroxidases produced by Pleurotus ostreatus in culture media composed of agro-residues was measured by visible spectrophotometry. The overall enzyme activity and its selectivity were separated by using spectral mapping technique followed by nonlinear mapping. The relationships between the parameters of enzyme production and the composition of culture media and fermentation time was assessed by stepwise regression analysis. Calculations proved that the addition of extract of straw to the culture media significantly decreased the overall production of both enzymes, whereas the selectivity of enzyme production was influenced by amount of potato extract and the concentration of total sugar in the culture media. Enzyme activity depended quadratically on the fermentation time.