Cognitive optimization of microbial PHB production in an optimally dispersed bioreactor by single and mixed cultures

Cognitive (or intelligent) models are often superior to mechanistic models for nonideal bioreactors. Two kinds of cognitive models—cybernetic and neural—were applied recently to fed-batch fermentation by Ralstonia eutropha in a bioreactor with optimum finite dispersion. In the present work, these models have been applied in simulation studies of co-cultures of R. eutropha and Lactobacillus delbrueckii. The results for both cognitive and mechanistic models have been compared with single cultures. Neural models were the most effective for both types of cultures and mechanistic models the least effective. Simulations with co-culture fermentations predicted more PHB than single cultures with all three types of models. Significantly, the predicted enhancements in PHB concentration by cognitive methods for mixed cultures were four to five times larger than the corresponding increases in biomass concentration. Further improvements are possible through a hybrid combination of all three types of models.     

On‐line adaptive metabolic flux analysis: Application to PHB production by mixed microbial cultures

In this work, an algorithm for on‐line adaptive metabolic flux analysis (MFA) is proposed and applied to polyhydroxybutyrate (PHB) production by mixed microbial cultures (MMC). In this process, population dynamics constitutes an important source of perturbation to MFA calculations because some stoichiometric and energetic parameters of the underlying metabolic network are continuously changing over time. The proposed algorithm is based on the application of the observer‐based estimator (OBE) to the central MFA equation, whereby the role of the OBE is to force the accumulation of intracellular metabolites to converge to zero by adjusting the values of unknown network parameters. The algorithm was implemented in a reactor equipped with on‐line analyses of dissolved oxygen and carbon dioxide through respirometric and titrimetric measurements. The oxygen and carbon dioxide fluxes were measured directly, whereas acetate, PHB, and sludge production fluxes were estimated indirectly using a projection of latent structures model calibrated a priori with off‐line measurements. The algorithm was implemented in a way that the network parameters associated with biosynthesis were adjusted on‐line. The algorithm proofed to converge exponentially with the steady state error always below 1 mmol/L. The estimated fluxes passed the consistency index test for experimental error variances as low as 1%. The comparison of measured and estimated respiratory coefficient and of the theoretical and estimated yield of sludge on acetate further confirmed the metabolic consistency of the parameters that were estimated on‐line. © 2009 American Institute of Chemical Engineers Biotechnol. Prog., 2009     

Perspectives in the modeling and optimization of PHB production by pure and mixed cultures

Poly(beta-hydroxybutyrate) or PHB is an important member of the family of polyhydroxyalkanoates with properties that make it potentially competitive with synthetic polymers. In addition, PHB is biodegradable. While the biochemistry of PHB synthesis by microorganisms is well known, improvement of large-scale productivity requires good fermentation modeling and optimization. The latter aspect is reviewed here. Current models are of two types: (i) mechanistic and (ii) cybernetic. The models may be unstructured or structured, and they have been applied to single cultures and co-cultures. However, neither class of models expresses adequately all the important features of large-scale non-ideal fermentations. Model-independent neural networks provide faithful representations of observations, but they can be difficult to design. So hybrid models, combining mechanistic, cybernetic and neural models, offer a useful compromise. All three kinds of basic models are discussed with applications and directions toward hybrid model development.     

Production of polyhydroxyalkanoates by mixed microbial cultures

Polyhydroxyalkanoates (PHAs) are biodegradable bioplastics formed from renewable resources, like sugars, with similar characteristics of polypropylene. These bioplastics are industrially produced by pure cultures using expensive pure substrates. These factors lead to a much higher selling price of PHAs compared to petroleum-based plastics, like polypropylene. The use of mixed cultures and cheap substrates (waste materials) can reduce costs of PHA production by more than 50%. Storage of PHAs by mixed populations occurs under transient conditions mainly caused by discontinuous feeding and variation in the electron donor/acceptor presence. In the last years the mechanisms of storage, metabolism and kinetics of mixed cultures have been studied. The maximum capacity of PHA storage and production rate is dependent on the substrate and on the operating conditions used. In this paper an overview and discussion of various mechanisms and processes for PHA production by mixed cultures is presented.     

On-line monitoring of recombinant bacterial cultures using multi-wavelength fluorescence spectroscopy

Multi-wavelength fluorescence spectroscopy was evaluated as a tool for on-line monitoring of recombinant Escherichia coli cultivations expressing human basic fibroblast growth factor (hFGF-2). The data sets for the various combinations of the excitation and emission spectra from batch cultivations were analyzed using principal component analysis. Chemometric models (the partial least squares method) were developed for correlating the fluorescence data and the experimentally measured variables such as the biomass and glucose concentrations as well as the carbon dioxide production rate. Excellent correlations were obtained for these variables for the calibration cultivations. The predictability of these models was further tested in batch and fed-batch cultivations. The batch cultivations were well predicted by the PLS models for biomass, glucose concentrations and carbon dioxide production rate (RMSEPs were respectively 5%, 7%, 9%). However, when tested for biomass concentrations in fed-batch cultivations (with final biomass three times higher than the highest calibration data) the models had good predictability at high growth rates (RMSEPs were 3% and 4%, respectively for uninduced and induced fed-batch cultivations), which was as good as for the batch cultivations used for developing the models (RMSEPs were 3% and 5%, respectively for uninduced and induced batch cultivations). The fed-batch cultivations performed at low growth rates exhibited much higher fluorescence for fluorophores such as flavin and NAD(P)H as compared to fed-batch cultivations at high growth rate. Therefore, the PLS models tended to over-predict the biomass concentrations at low growth rates. Obviously the cells changed their concentration of biogenic fluorophores depending on the growth rate. Although multi-wavelength fluorescence spectroscopy is a valuable tool for on-line monitoring of bioprocess, care must be taken to re-calibrate the PLS models at different growth rates to improve the accuracy of predictions.     

H2 production by mixed cultures

Production of H₂ from glucose by an anoxygenic phototrophic bacterium (Rhodobacter sphaeroides), a cyanobacterium (Synechococcus cedrorum) and a heterotrophic bacterium (Pseudomonas fluorescens) was tested individually and in mixed cultures of various combinations in light. H₂ production was maximal with a mixed culture of R. sphaeroides and P. fluorescens, which could be further enhanced by immobilization of the bacteria in alginate gel. Inhibition of H₂ photoproduction was observed in a mixture of S. cedrorum and P. fluorescens and a co-culture of all the three organisms.Ch. Sasikala and Ch. V. Ramana are and G. S. Prasad was with the Microbial Biotechnology Laboratory, Department of Botany, Osmania University, Hyderabad-500 007, India. G. S. Prasad is now with the Microbial Type Culture Collection Centre (MTCC), IMTECH, Chandigar, India.     

On-line and in-situ monitoring technology for cell density measurement in microbial and animal cell cultures

Commercially available on-line and in-situ devices for monitoring cell density are reviewed in this article. Principles of operation are described as well as capabilities of these probes in specific measurement applications based on literature reports. Pilot-scale experimental observations from three optical density probes, the Cerex, Monitek and Wedgewood designs, have been included for Escherichia coli fermentations. Requirements for future on-line and in-situ instruments are discussed as well as the impact of current limitations on widespread application.     

Exopolysaccharide production by free and immobilized microbial cultures

The batch production of different exopolysaccharides (alginate, xanthan, pullulan, dextran) by free and immobilized microbial cultures was investigated. First, conventional free-cell cultures were performed to obtain control fermentation parameters and macromolecular characteristics of exopolysaccharides. Then microbial cultures were immobilized in composite agar layer/microporous membrane structures and tested for polysaccharide production. The immobilized-cell system proved unsuitable for xanthan and pullulan production. Owing to the fouling of the microporous membrane by the polysaccharide, dextran production by immobilized Leuconostoc mesenteroides also was inefficient. More promising results have been obtained with immobilized Azotobacter vinelandii cultures. The amount of alginate produced by immobilized A. vinelandii represented about 60% of that recovered from a free-cell culture, whereas the polysaccharide yield reached 35% instead of 9% for the free counterpart. These results are compared to the macromolecular characteristics of exopolysaccharides.     

Degradation of polychlorinated biphenyls by mixed microbial cultures.

Three different enriched mixed cultures capable of degrading polychlorinated biphenylas were isolated from two soil samples and a river sediment, respectively. The predominant organisms found in all three mixed cultures were Alcaligenes odorans, Alcaligenes dentrificans, and an unidentified bacterium. The polychlorinated biphenyl isomers that were more water soluble and had lower chlorination were not only degraded at a faster rate than those that were less water soluble and had higher chlorination, but were also more completely utilized by these mixed cultures. This resulted in the presence in the environment of polychlorinated biphenyl residues consisting mainly of higher-chlorinated isomers. A form of cometabolism of polychlorinated biphenyls was also found with these cultures in the presence of acetate as the cosubstrate.     

Degradation of polychlorinated biphenyls by mixed microbial cultures.

Three different enriched mixed cultures capable of degrading polychlorinated biphenylas were isolated from two soil samples and a river sediment, respectively. The predominant organisms found in all three mixed cultures were Alcaligenes odorans, Alcaligenes dentrificans, and an unidentified bacterium. The polychlorinated biphenyl isomers that were more water soluble and had lower chlorination were not only degraded at a faster rate than those that were less water soluble and had higher chlorination, but were also more completely utilized by these mixed cultures. This resulted in the presence in the environment of polychlorinated biphenyl residues consisting mainly of higher-chlorinated isomers. A form of cometabolism of polychlorinated biphenyls was also found with these cultures in the presence of acetate as the cosubstrate.     

Polyhydroxybutyrate production from lactate using a mixed microbial culture

In this study we investigated the use of lactate and a lactate/acetate mixture for enrichment of poly-3-hydroxybutyrate (PHB) producing mixed cultures. The mixed cultures were enriched in sequencing batch reactors (SBR) that established a feast-famine regime. The SBRs were operated under conditions that were previously shown to enable enrichment of a superior PHB producing strain on acetate (i.e., 12 h cycle length, 1 day SRT and 30°C). Two new mixed cultures were eventually enriched from activated sludge. The mixed culture enriched on lactate was dominated by a novel gammaproteobacterium. This enrichment can accumulate over 90 wt% PHB within 6 h, which is currently the best result reported for a bacterial culture in terms of the final PHB content and the biomass specific PHB production rate. The second mixed culture enriched on a mixture of acetate and lactate can produce up to 84 wt% PHB in just over 8 h. The predominant bacterial species in this culture were Plasticicumulans acidivorans and Thauera selenatis, which have both been reported to accumulate large amounts of PHB. The data suggest that P. acidivorans is a specialist on acetate conversion, whereas Thauera sp. is a specialist on lactate conversion. The main conclusion of this work is that the use of different substrates has a direct impact on microbial composition, but has no significant effect on the functionality of PHB production process.     

Modeling of the mixed culture and periodic control for PHB production

The unstructured mathematical model was developed in the present investigation for the mixed culture, where the metabolites produced by one microorganism is assimilated by the other microorganism. For this, we specifically employed such model system in which sugars such as glucose were converted to lactate by Lactobacillus delbrueckii and the lactate was converted in turn to poly-β-hydroxybutyrate (PHB) by Ralstonia eutropha in one fermentor. Several batch and fed-batch culture experiments were conducted using each microorganism at different dissolved oxygen (DO) concentrations. Those experimental data were then fitted to the mathematical model, which can describe the dynamics of a mixed culture. Some of the model parameters were expressed as functions of DO concentrations, and some of the other model parameters were tuned based on the mixed culture experiments. The model developed describes the effects of such concentrations of glucose, lactate, DO, and NH₃ on the dynamic behavior of such concentrations as both microorganisms, glucose, lactate, and PHB. Optimal operating condition was then investigated using the model developed. It was found that the periodic change in DO concentration improved such performance as PHB yield, and it was verified by experiments. The optimal NH₃ concentration profile was also obtained for the efficient PHB production by the application of the maximum principle.     

On-line monitoring of microbial volatile metabolites by proton transfer reaction-mass spectrometry

A method for analysis of volatile organic compounds (VOCs) from microbial cultures was established using proton transfer reaction-mass spectrometry (PTR-MS). A newly developed sampling system was coupled to a PTR-MS instrument to allow on-line monitoring of VOCs in the dynamic headspaces of microbial cultures. The novel PTR-MS method was evaluated for four reference organisms: Escherichia coli, Shigella flexneri, Salmonella enterica, and Candida tropicalis. Headspace VOCs in sampling bottles containing actively growing cultures and uninoculated culture medium controls were sequentially analyzed by PTR-MS. Characteristic marker ions were found for certain microbial cultures: C. tropicalis could be identified by several unique markers compared with the other three organisms, and E. coli and S. enterica were distinguishable from each other and from S. flexneri by specific marker ions, demonstrating the potential of this method to differentiate between even closely related microorganisms. Although the temporal profiles of some VOCs were similar to the growth dynamics of the microbial cultures, most VOCs showed a different temporal profile, characterized by constant or decreasing VOC levels or by single or multiple peaks over 24 h of incubation. These findings strongly indicate that the temporal evolution of VOC emissions during growth must be considered if characterization or differentiation based on microbial VOC emissions is attempted. Our study may help to establish the analysis of VOCs by on-line PTR-MS as a routine method in microbiology and as a tool for monitoring environmental and biotechnological processes.     

In situ 2D fluorometry and chemometric monitoring of mammalian cell cultures

The main objective of the present study was to investigate the use of in situ 2D fluorometry for monitoring key bioprocess variables in mammalian cell cultures, namely the concentration of viable cells and the concentration of recombinant proteins. All studies were conducted using a recombinant Baby Hamster Kidney (BHK) cell line expressing a fusion glycoprotein IgG1-IL2 cultured in batch and fed-batch modes. It was observed that the intensity of fluorescence signals in the excitation/emission wavelength range of amino acids, vitamins and NAD(P)H changed along culture time, although the dynamics of single fluorophors could not be correlated with the dynamics of the target state variables. Therefore, multivariate chemometric modeling was adopted as a calibration methodology. 2D fluorometry produced large volumes of redundant spectral data, which were first filtered by principal components analysis (PCA). Then, a partial least squares (PLS) regression was applied to correlate the reduced fluorescence maps with the target state variables. Two validation strategies were used to evaluate the predictive capacity of the developed PLS models. Accurate estimations of viable cells density (r(2) = 0.95; 99.2% of variance captured in the training set; r(2) = 0.91; 97.7% of variance captured in the validation set) and of glycoprotein concentration (r(2) = 0.99 and 99.7% of variance captured in the training set; r(2) = 0.99 and 99.3% of variance captured in the validation set) were obtained over a wide range of reactor operation conditions. The results presented herein confirm that 2D fluorometry constitutes a reliable methodology for on-line monitoring of viable cells and recombinant protein concentrations in mammalian cell cultures.     

Advance on the production of polyhydroxyalkanoates by mixed cultures

Polyhydroxyalkanoates (PHAs) are the polymers of hydroxyalkanoates that accumulate as carbon/energy or reducing-power storage material in various microorganisms. PHAs have attracted considerable attention as biodegradable substitutes for conventional polymers. Until now, however, industrial production of PHAs has encountered only limited success. The main barrier to the replacement of synthetic plastics by PHAs has been the higher cost. The use of mixed cultures and renewable sources obtained from waste organic carbon can substantially decrease the cost of PHA and increase their market potential. This work reviews two main methods of PHA production by mixed cultures, anaerobic-aerobic processing and aerobic transient feeding processing, and analyzed the metabolic and effective factors.     

Metabolic modelling of mixed culture anaerobic microbial processes

Biochemical process modelling (BPM) is at the process level and driven by observations while cellular level modelling (CLM) is at the cellular level and is driven by knowledge about the genetics and microbial capability.

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Advance on the production of polyhydroxyalkanoates by mixed cultures

Polyhydroxyalkanoates (PHAs)are the polymers of hydroxyalkanoates that accumulate as carbon/energy or reducing-power storage material in various microorganisms.PHAs have attracted considerable attention as biodegradable substitutes for conventional polymers.Until now,however,industrial production of PHAs has encountered only limited success.The main barrier to the replacement of synthetic plastics by PHAs has been the higher cost.The use of mixed cultures and renewable sources obtained from waste organic carbon can substantially decrease the cost of PHA and increase their market potential.This work reviews two main methods of PHA production by mixed cultures,anaerobicaerobic processing and aerobic transient feeding processing,and analyzed the metabolic and effective factors.     

On-line monitoring of growth of Escherichia coli in batch cultures by bioluminescence

Bioluminescence was used to monitor growth of Escherichia coli in batch cultures on-line. Light emission of a strain engineered for constitutive bioluminescence was monitored with a simple set-up consisting of a photodiode, a photodetector amplifier and a recorder. Bioluminescence and colony forming units (CFU) of the cultures increased and decreased proportionally and were correlated during every growth phase at temperatures between 28 °C and 40 °C. Up to the late log (deceleration) phase, both light emission and CFU increased rapidly. Beyond the stationary phase these characteristics decreased very slowly at lower temperatures, while at higher ones they declined more rapidly. Towards the end of the cultivation, light emission of the cultures dropped to undetectable levels, even though CFU were recovered. This was particularly marked at lower temperatures where non-luminescent cultures retained very high CFU. This indicates that the actual metabolism of cells in a culture can be at a very low level or completely shut down, yet cells retain their capability to be culturable. The on-line technology described here has a number of potential uses in the laboratory and industry. Received: 30 September 1999 / Received revision: 29 November 1999 / Accepted: 3 December 1999     

On-line monitoring of cell mass in mammalian cell cultures by acoustic densitometry

Acoustic resonance densitometry (ARD) provides a highly reproducible and stable method for on-line measurement of culture biomass density. The technique provides a direct determination of changes in relative density of culture medium and cell mass. At cell concentrations higher than 10(6) cells mL(-1)this method can replace cell counts and provide a continuous measure of total cell mass. In cultures of hybridomas or U937 human lymphoma cells, the ARD value correlates well with cell number except when the average cell size changes during culture. It is argued that cell mass determined by ARD rather than cell number should be used as the basis for measurements of specific biological activity.