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.     

Lipase production and Penicillium simplicissimum morphology in solid-state and submerged fermentations

A comparative study of Penicillium simplicissimum morphology and lipase production was performed using solid-state (SSF) and submerged (SmF) fermentation. SSF was carried out on babassu cake as culture medium and SmF on a semi-synthetic medium and a medium based on suspended babassu cake grains. Yield of product on biomass, specific activity and conidia production were 3.3-, 1.3- and 2-fold higher in SSF. In SmF, the type of fungus growth differed according to the medium. Using the semi-synthetic medium, the fungus formed densely interwoven mycelial masses without conidia production, whereas using the babassu-based medium the fungus formed free mycelia and adhered to the surfaces of the grains, producing conidia. The results show that babassu cake induces conidiation in SmF. In SSF, the fungus not only grew on the surface of the grains, producing conidia abundantly, but also effectively colonized and penetrated the babassu particles. The high conidia production and lipase productivity in SSF may be related to the low availability of nutrients or to other stimuli associated with this type of fermentation. Thus, the high production of the thermostable P. simplicissimum lipase, using a non-supplemented, low-cost agro-industrial residue as the culture medium, demonstrates the biotechnological potential of SSF for the production of industrial enzymes.     

On-line study of fungal morphology during submerged growth in a small flow-through cell

A flow-through cell is designed to measure the growth kinetics of hyphae of Aspergillus oryzae grown submerged in a well controlled environment. The different stages of the growth process are characterized, from the spore to the fully developed hyphal element with up to 60 branches and a total length lt up to 10,000 micrometer. Spore swelling is found to occur without change in the form of the spore (circularity index constant at about 1.06) and the spore volume probably increases exponentially. The germ tube appears after about 4 h. The branching frequency and the rate of germ tube extension is determined. After about 10 h growth at a glucose concentration of 250 mg L-1, 6-7 branches have been set, and both the total hyphal length lt and the number of tips increase exponentially with time. The specific growth rate of the hyphae is 0. 33 h-1 while the average rate of the extension of the growing tips approaches 55 micrometer h-1. The growth kinetics for all the branches on the main hypha have also been found. The main hypha and all the branches grow at a rate which can be modeled by saturation kinetics with respect to the branch length and with nearly equal final tip speeds (160 micrometer h-1). Branches set near the apical tip of the main hypha attain their final tip speed in the shortest time, i.e., the value of the saturation parameter is small. Finally, the influence of substrate (glucose) concentration cs on the values of the morphological parameters has been determined. It is found that saturation type kinetics can be used to describe the influence of cs on the growth. Experiments with recirculation of effluent from the cell back to the inlet strongly suggest that the fungus secretes an inducer for growth and branching.     

Effect of agitation intensities on fungal morphology of submerged fermentation

Both parallel fermentations with Aspergillus awamori (CBS 115.52) and a literature study on several fungi have been carried out to determine a relation between fungal morphology and agitation intensity. The studied parameters include hyphal length, pellet size, surface structure or so-called hairy length of pellets, and dry mass per-wet-pellet volume at different specific energy dissipation rates. The literature data from different strains, different fermenters, and different cultivation conditions can be summarized to say that the main mean hyphal length is proportional to the specific energy dissipation rate according to a power function with an exponent of -0.25 +/- 0.08. Fermentations with identical inocula showed that pellet size was also a function of the specific energy dissipation rate and proportional to the specific energy dissipation rate to an exponent of -0.16 +/- 0.03. Based on the experimental observations, we propose the following mechanism of pellet damage during submerged cultivation in stirred fermenters. Interaction between mechanical forces and pellets results in the hyphal chip-off from the pellet outer zone instead of the breakup of pellets. By this mechanism, the extension of the hyphae or hair from pellets is restricted so that the size of pellets is related to the specific energy dissipation rate. Hyphae chipped off from pellets contribute free filamentous mycelia and reseed their growth. So the fraction of filamentous mycelial mass in the total biomass is related to the specific energy dissipation rate as well.To describe the surface morphology of pellets, the hyphal length in the outer zone of pellets or the so-called hairy length was measured in this study. A theoretical relation of the hairy length with the specific energy dissipation rate was derived. This relation matched the measured data well. It was found that the porosity of pellets showed an inverse relationship with the specific energy dissipation rate and that the dry biomass per-wet-pellet volume increased with the specific energy dissipation rates. This means that the tensile strength of pellets increased with the increase of specific energy dissipation rate. The assumption of a constant tensile strength, which is often used in literature, is then not valid for the derivation of the relation between pellet size and specific energy dissipation rate. The fraction of free filamentous mycelia in the total biomass appeared to be a function of the specific energy dissipation in stirred bioreactors. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 55: 715-726, 1997.     

Effects of dissolved oxygen tension and mechanical forces on fungal morphology in submerged fermentation

The effects of dissolved oxygen tension and mechanical forces on fungal morphology were both studied in the submerged fermentation of Aspergillus awamori. Pellet size, the hairy length of pellets, and the free filamentous mycelial fraction in the total biomass were found to be a function of the mechanical force intensity and to be independent of the dissolved oxygen tension provided that the dissolved oxygen tension was neither too low (5%) nor too high (330%). When the dissolved oxygen concentration was close to the saturation concentration corresponding to pure oxygen gas, A. awamori formed denser pellets and the free filamentous mycelial fraction was almost zero for a power input of about 1 W/kg. In the case of very low dissolved oxygen tension, the pellets were rather weak and fluffy so that they showed a very different appearance. The amount of biomass per pellet surface area appeared to be affected only by the dissolved oxygen tension and was proportional to the average dissolved oxygen tension to the power of 0.33. From this it was concluded that molecular diffusion was the dominant mechanism for oxygen transfer in the pellets and that convection and turbulent flow in the pellets were negligible in submerged fermentations. The biomass per wet pellet volume increased with the dissolved oxygen tension and decreased with the size of the pellets. This means that the smaller pellets formed under a higher dissolved oxygen tension had a higher intrinsic strength. Correspondingly, the porosity of the pellets was a function of the dissolved oxygen tension and the size of pellets. Within the studied range, the void fraction in the pellets was high and always much more than 50%.     

丝状真菌发酵生产中形态的影响与发酵罐设计

就丝状真菌深层发酵过程中菌体形态对发酵液粘稠的影响,发酵液粘稠带来的不利因素,菌体形态与代谢产物生产间的关系及针对丝状真菌的发酵罐设计等方面进行了论述。     

Mycelial morphology and fungal protein production from starch processing wastewater in submerged cultures of Aspergillus oryzae

Three strains of Aspergillus oryzae were used for fungal protein production from starch processing wastewater (SPW) as part of a comprehensive SPW utilization and treatment program. The mycelial morphologies of the three strains varied from fluffy, clumpy mycelia to compact pellets with various strains and cultivation conditions of growth pH, inoculum quantity and superficial air velocity in an air lift bioreactor process. An inoculum technique was developed to ensure a desirable morphology with an improved fungal protein yield. Experimental relationship between the morphology and the yield revealed that the formation of small compact pellets under designed cultivation conditions favoured higher fungal protein yields, easier product separation and better process operation.     

Terbinafine inhibits Cryptococcus neoformans growth and modulates fungal morphology

Cryptococcus neoformans is an encapsulated fungus that causes cryptococcosis. Central nervous system infection is the most common clinical presentation followed by pulmonary, skin and eye manifestations. Cryptococcosis is primarily treated with amphotericin B (AMB), fluconazole (FLC) and itraconazole (ITC). In the present work, we evaluated the in vitro effect of terbinafine (TRB), an antifungal not commonly used to treat cryptococcosis. We specifically examined the effects of TRB, either alone or in conjunction with AMB, FLC and ITC, on clinical C. neoformans isolates, including some isolates resistant to AMB and ITC. Broth microdilution assays showed that TRB was the most effective drug in vitro. Antifungal combinations demonstrated synergism of TRB with AMB, FLC and ITC. The drug concentrations used for the combination formulations were as much as 32 and 16-fold lower than the minimum inhibitory concentration (MIC) values of FLC and AMB alone, respectively. In addition, calcofluor white staining revealed the presence of true septa in hyphae structures that were generated after drug treatment. Ultrastructural analyses demonstrated several alterations in response to drug treatment, such as cell wall alterations, plasma membrane detachment, presence of several cytoplasmic vacuoles and mitochondrial swelling. Therefore, we believe that the use of TRB alone or in combination with AMB and azoles should be explored as an alternative treatment for cryptococcosis patients who do not respond to standard therapies.     

Dissolved oxygen measurements in pilot- and production-scale novobiocin fermentations

Dissolved oxygen measurements were made in pilot (20 and 250 l.) and production scale (15,000 l.) novobiocin fermentations. Bulk mixing was found to be incomplete in pilot tanks with turbine impellers of D/T = 0.40 (where D is impeller diameter, and T is tank diameter) but appeared homogeneous with impellers of D/T = 0.69. In the former case, the respiration rate was presumably limited by insufficient oxygen supply in areas of poor bulk mixing, whereas, in the latter case, the major resistance was between the bulk of the liquid and the cell (intraclump resistance). Higher agitator speeds decreased the gas–liquid resistance proportionally more than they reduced the liquid-cell resistance. In production fermentors, dissolved oxygen measurements indicated that bulk mixing was complete with each of the three impeller sizes tested (D/T = 0.28, 0.33, and 0.43), but that the respiration rate was again limited, mainly by a resistance between the bulk of the liquid and the cell.     

Cellulase production by Aspergillus niger in biofilm, solid-state, and submerged fermentations

Cellulase production by Aspergillus niger was compared in three different culture systems: biofilm, solid-state, and submerged fermentation. Biofilm and solid-state fermentations were carried out on perlite as inert support, and lactose was used as a carbon source in the three culture systems. In cryo-scanning electron microscopy, biofilm and solid-state cultures gave similar morphological patterns and confirmed that both spore first attachment and hyphal adhered growth are helped by the production of an adhesive extracellular matrix. Biofilm cultures produced higher cellulase activities than those in submerged and solid-state cultures (1,768, 1,165, and 1,174 U l⁻¹, respectively). Although biofilm cultures grew less than the other cultures, they produced significantly higher cellulase yields (370, 212, and 217 U g⁻¹ lactose, respectively) and volumetric productivities (24, 16, and 16 U l⁻¹ h⁻¹, respectively). Likewise, endoglucanase and xylanase activities were higher in biofilm cultures. Under the conditions tested, it seems that fungal attached growth on perlite may favor better enzyme production. Biofilms are efficient systems for cellulase production and may replace solid-state fermentation. Biofilm fermentation holds promise for further optimization and development. The results of this work reveal that fungal biofilms may be used for the commercial production of cellulase employing the technology developed for submerged fermentation at high cell densities.     

An investigation of the physico-chemical basis of foaming in fungal fermentations

A detailed physico-chemical analysis of two foaming fungal fermentations was carried out to identify that key groups of compounds responsible for foam formation. Fermentations were carried out on a 20-L scale in a stirred aerated tank, over 7 days, using a commercial, defined medium. The organisms investigated were Penicillium herqueii, a hyphomycete, and an unidentified Ingoldian fungus. Samples of broth and, where possible, foam were analyzed to determine which groups of compounds were concentrated into generated foams. Surface tension, bulk viscosity, and antifoam A concentration were additionally determined in broth samples. To date the cause of foaming in fermentations has been attributed to the surfactant properties of extracellular proteins. This assumption was tested and found to be incomplete as many additional groups of biochemicals were found to be enriched into the foam. The results of the investigation revealed the presence of proteins, carbohydrates, alpha-keto acids, and lipophilic biosurfactants, particularly extracellular pigments, enriched within stable foams. (c) 1994 John Wiley & Sons, Inc.     

L(+)-Lactic acid from sweet sorghum by submerged and solid-state fermentations

Sweet sorghum was used as the raw material for the lactate production by a strain of Lactobacillus paracasei. The submerged conversion of sugar juice obtained from sweet sorghum by extraction could be accomplished with the same efficiency as observed in a control experiment with MRS-glucose medium (final lactate concentration of 88–106 g/l, lactate yield of 91–95%, duration of the fermentation of 24–32 h). Finely ground stalks of sorghum served as the substrate in the solid-state fermentation. The lactate accumulation in the solid medium and the lactate yield were optimized up to values comparable with the results from the submerged fermentation (final lactate concentration of 90 g/kg, lactate yield of 91–95%). However, the duration of the fermentation amounted to 120–200 h in the solid-state process. The data from a series of experiments performed at variable values of temperatures between 30°C and 36°C and initial sugar concentrations between 60 g/kg and 115 g/kg, and degrees of moisture between 78% and 82% was the basis of a polynomial multidimensional regression. As a result, simple three-dimensional model functions were obtained for the maximum productivity of lactate formation, the lactate yield and the time required for a 90% conversion.     

Characterization of pellet morphology during submerged growth of Streptomyces tendae by image analysis

Many filamentous bacteria and fungi tend to form pellets, or mixtures of dispersed mycelium and pellets in liquid fermentation broths. In some cases, a specific kind of morphology is required for optimum product yield. When quantitative analysis and characterization of the pellet morphology are needed, an image processing system can be used. It allows a fast and reproducible analysis of the frequency distribution of pellet size, mean pellet size, contents of pellets, or their shape. The use of such a system allows for an on-line analysis. For a demonstration of the method, results of two fermentations of Streptomyces tendae are shown.     

Modeling product formation in anaerobic mixed culture fermentations

The anaerobic conversion of organic matter to fermentation products is an important biotechnological process. The prediction of the fermentation products is until now a complicated issue for mixed cultures. A modeling approach is presented here as an effort to develop a methodology for modeling fermentative mixed culture systems. To illustrate this methodology, a steady-state metabolic model was developed for prediction of product formation in mixed culture fermentations as a function of the environmental conditions. The model predicts product formation from glucose as a function of the hydrogen partial pressure (P(H2)), reactor pH, and substrate concentration. The model treats the mixed culture as a single virtual microorganism catalyzing the most common fermentative pathways, producing ethanol, acetate, propionate, butyrate, lactate, hydrogen, carbon dioxide, and biomass. The product spectrum is obtained by maximizing the biomass growth yield which is limited by catabolic energy production. The optimization is constrained by mass balances and thermodynamics of the bioreactions involved. Energetic implications of concentration gradients across the cytoplasmic membrane are considered and transport processes are associated with metabolic energy exchange to model the pH effect. Preliminary results confirmed qualitatively the anticipated behavior of the system at variable pH and P(H2) values. A shift from acetate to butyrate as main product when either P(H2) increases and/or pH decreases is predicted as well as ethanol formation at lower pH values. Future work aims at extension of the model and structural validation with experimental data.     

Cell growth and extracellular enzyme synthesis in fermentations

The synthesis of extracellular enzymes by microorganisms frequently occurs under genetic control. A simple two-parameter model is developed describing the degree of repression or induction in fermentation media. The case of substrate utilization by an extracellular enzyme was analyzed for a vegetable oil-lipase-yeast system. It is shown that fatty acids released by the lipase may accumulate in the early stage of growth and exert an influence on the limiting after which relatively little repression or induction takes place. Expressions are also derived for growth and extracellular enzyme synthesis in single-and multistage continuous cultures. When the cells grow on a directly available soluble substrate, the specific enzyme synthesis is maximal at low dilution rates in the case of repression and at high dilution rates in the case of induction. If the substrate is not directly available, a single continuous stirred tank reactor stage may not be sufficient for efficient substrate utilization; for fermentation processes where an insoluble has to be broken down before the cells can assimilate it, a plug flow type fermentor rather than a mixed chemostat may prove more satisfactory.     

Aspergillus oryzae in solid-state and submerged fermentations. Progress report on a multi-disciplinary project

We report the progress of a multi-disciplinary research project on solid-state fermentation (SSF) of the filamentous fungus Aspergillus oryzae. The molecular and physiological aspects of the fungus in submerged fermentation (SmF) and SSF are compared and we observe a number of differences correlated with the different growth conditions. First, the aerial hyphae which occur only in SSFs are mainly responsible for oxygen uptake. Second, SSF is characterised by gradients in temperature, water activity and nutrient concentration, and inside the hyphae different polyols are accumulating. Third, pelleted growth in SmF and mycelial growth in SSF show different gene expression and protein secretion patterns. With this approach we aim to expand our knowledge of mechanisms of fungal growth on solid substrates and to exploit the biotechnological applications.     

Electrooptical measurements for monitoring metabolite fluxes in acetone-butanol-ethanol fermentations

Anisotropy of electrical polarizability in Clostridium acetobutylicum cells during pH 5 controlled acetone butanol ethanol fermentations was observed. Cell length was determined from the electrooptical data. Mean length was determined as being 2.5 microm in the growth phase and 3.5 microm in the early stationary phase. Based on the obtained frequency dispersion of polarizability anisotropy (FDPA) in the range of 190 to 2,100 kHz, the switch from the acidogenic to the solventogenic phase could be monitored. The slope of polarizability versus the frequency made it possible to differentiate between phases of dominating acid and solvent production. Metabolite fluxes determined from concentration measurements correlated well to the polarizability. A partial least-squares (PLS) model was established and validated by applying data from several fermentations. The root mean square error of calibration (RMSEC) was 0.09 for the acid fluxes and 0.11 for the solvent fluxes. The root mean square error of prediction (RMSEP) was 0.20 for acid fluxes and 0.24 for solvent fluxes. The ratio of polarizability at high and low frequencies correlated to the ongoing sporulation process. At ratios below 0.25, spore formation in the cells became visible under the microscope. The advantage of using electrooptical measurements is the ability to observe metabolite fluxes rather than concentrations, which provides useful information on productivity during a bioprocess.     

Bioprocessing strategies to improve heterologous protein production in filamentous fungal fermentations

Filamentous fungi have long been used for the production of metabolites and enzymes. With developments in genetic engineering and molecular biology, filamentous fungi have also achieved increased attention as hosts for recombinant DNA. However, the production levels of non-fungal proteins are usually low. Despite the achievements obtained using molecular tools, the heterologous protein loss caused by extracellular fungal protease degradation persists. This review provides an overview of the potential bioprocessing strategies that can be applied to inhibit protease activity thereby enhancing heterologous protein production.     

Microbial growth kinetics of fed-batch fermentations

Summary Fed-batch fermenters are generally operated with the addition of small doses of nutrients, therefore the volume of the fermentation broth increases with time. Batch fermenters generally contain and almost constant volume of broth and a logistic equation has been commonly employed to simulate microbial growth in them. Mass balances were determined with fed-batch fermentation to obtain expressions which account for the effect of volume increase and the subsequent dilution of the biomass. A growth rate expression was obtained for fed-batch fermentations. The new expression was very similar to the logistic equation. Therefore an anology between the values of the parameters of the new model and of the logistic equation was sought. The new model was also employed to simulate six sets of data from the literature and satisfactory results were obtained.