Fungal morphology and metabolite production in submerged mycelial processes

The use of fungi for the production of commercial products is ancient, but it has increased rapidly over the last 50 years. Fungi are morphologically complex organisms, differing in structure at different times in their life cycle, differing in form between surface and submerged growth, differing also with the nature of the growth medium and physical environment. Many genes and physiological mechanisms are involved in the process of morphogenesis. In submerged culture, a large number of factors contribute to the development of any particular morphological form. Factors affecting morphology include the type and concentration of carbon substrate, levels of nitrogen and phosphate, trace minerals, dissolved oxygen and carbon dioxide, pH and temperature. Physical factors affecting morphology include fermenter geometry, agitation systems, rheology and the culture modes, whether batch, fed-batch or continuous. In many cases, particular morphological forms achieve maximum performance. It is a very difficult task to deduce unequivocal general relationships between process variables, product formation and fungal morphology since too many parameters influence these interrelationships and the role of many of them is still not fully understood. The use of automatic image analysis systems during the last decade proved an invaluable tool for characterizing complex mycelial morphologies, physiological states and relationships between morphology and productivity. Quantified morphological information can be used to build morphologically structured models of predictive value. The mathematical modeling of the growth and process performance has led to improved design and operation of mycelial fermentations and has improved the ability of scientists to translate laboratory observations into commercial practice. However, it is still necessary to develop improved and new experimental techniques for understanding phenomena such as the mechanisms of mycelial fragmentation and non-destructive measurement of concentration profiles in mycelial aggregates. This would allow the establishment of a process control on a physiological basis. This review is focused on the factors influencing the fungal morphology and metabolite production in submerged culture.

Inhibitory effect of carbon dioxide on the fed-batch culture of Ralstonia eutropha: evaluation by CO2 pulse injection and autogenous CO2 methods

In order to see the effect of CO(2) inhibition resulting from the use of pure oxygen, we carried out a comparative fed-batch culture study of polyhydroxybutyric acid (PHB) production by Ralstonia eutropha using air and pure oxygen in 5-L, 30-L, and 300-L fermentors. The final PHB concentrations obtained with pure O(2) were 138.7 g/L in the 5-L fermentor and 131.3 g/L in the 30-L fermentor, which increased 2.9 and 6.2 times, respectively, as compared to those obtained with air. In the 300-L fermentor, the fed-batch culture with air yielded only 8.4 g/L PHB. However, the maximal CO(2) concentrations in the 5-L fermentor increased significantly from 4.1% (air) to 15.0% (pure O(2)), while it was only 1.6% in the 30-L fermentor with air, but reached 14.2% in the case of pure O(2). We used two different experimental methods for evaluating CO(2) inhibition: CO(2) pulse injection and autogenous CO(2) methods. A 10 or 22% (v/v) CO(2) pulse with a duration of 3 or 6 h was introduced in a pure-oxygen culture of R. eutropha to investigate how CO(2) affects the synthesis of biomass and PHB. CO(2) inhibited the cell growth and PHB synthesis significantly. The inhibitory effect became stronger with the increase of the CO(2) concentration and pulse duration. The new proposed autogenous CO(2) method makes it possible to place microbial cells under different CO(2) level environments by varying the gas flow rate. Introduction of O(2) gas at a low flow rate of 0.42 vvm resulted in an increase of CO(2) concentration to 30.2% in the exit gas. The final PHB of 97.2 g/L was obtained, which corresponded to 70% of the PHB production at 1.0 vvm O(2) flow rate. This new method measures the inhibitory effect of CO(2) produced autogenously by cells through the entire fermentation process and can avoid the overestimation of CO(2) inhibition without introducing artificial CO(2) into the fermentor.

Growth of filamentous fungi in submerged culture: problems and possible solutions

Filamentous fungi are important organisms industrially and continue to attract research interest as microbiologists attempt to overcome the problems associated with their behavior in submerged culture. This review critically examines the literature describing these problems and where available suggests possible solutions to them. The influence of the chemical and physical environment on culture morphology, the process engineering challenges presented by different fungal morphologies, and the relationship between fungal morphology and metabolite production are all discussed.

Instrumentation of biotechnological processes

Modern bioprocesses are monitored by on-line sensing devices mounted either in situ or externally. In addition to sensor probes, more and more analytical subsystems are being exploited to monitor the state of a bioprocess on-line and in real time. Some of these subsystems deliver signals that are useful for documentation only, other, less delayed systems generate signals useful for closed loop process control. Various conventional and non-conventional monitoring instruments are evaluated; their usefulness, benefits and associated pitfalls are discussed.

Indirect methods for characterization of carbon dioxide levels in fermentation broth

Various factors which influence dissolved carbon dioxide levels were indirectly evaluated in pilot scale and laboratory studies. For pilot scale studies, off-gas carbon dioxide (percentage in exit air) was measured using a mass spectrometer and then its potential impact on dissolved carbon dioxide concentrations qualitatively examined. Greater volumetric air flowrates reduced off-gas carbon dioxide levels more effectively at lower airflow ranges and thus lowered expected dissolved carbon dioxide levels through gas stripping. Lower broth pH values decreased off-gas carbon dioxide levels but increased expected dissolved carbon dioxide levels due to the pH-dependence of the gas/liquid carbon dioxide equilibrium. While back-pressure increases had an insignificant effect on off-gas carbon dioxide levels, they directly affected expected dissolved carbon dioxide levels according to Henry's law. Laboratory studies, conducted using both uninoculated and inoculated fermentation media, quantified the response of the media to pH changes with bicarbonate addition, specifically its buffering capacity. This effect then was related qualitatively to expected dissolved carbon dioxide levels. Higher dissolved carbon dioxide levels, as demonstrated by reduced pH changes with bicarbonate addition, thus would be expected for salt solutions of increased ionic strength and higher protein content media. In addition, pH changes with greater bicarbonate additions declined for fermentation samples taken over the course of a one week cultivation, most likely due to the higher protein content associated with biomass growth. The presence of weak acids/bases initially in the media or formed as metabolic by products, as well as the concentration of buffering ions such as phosphate, also were believed to be important contributing elements to the buffering capacity of the solution.

Rheology of filamentous fermentations

The performance of a bioreactor containing a filamentous fermentation broth is greatly influenced by the rheological properties of the broth. These properties are determined mainly by the concentration of biomass, its growth rate and morphology. Included in the morphology are such factors as the geometry of hyphae (length, diameter, branching frequency), hyphal flexibility and hyphal-hyphal interactions, which can all be affected by the operational design of the reactor. Thus, correlations describing viscosity as a function of biomass only are of limited value. A better understanding of the relations between morphology and rheology may be achieved by a combination of rheological and morphological studies. Rheological properties are normally determined using off-line measurements in-spite of associated problems with sample treatment influencing the results. Equipment for dynamic, on-line, measurement of morphology and rheology is available, but little used in filamentous fermentations. Controlling the rheological properties of mycelial fermentations may be difficult because of the great number of factors influencing mycelial development and/or hyphal-hyphal interactions.Polymer solutions are often used to simulate flow behaviour of filamentous fermentations and scale-up and mass transfer considerations are based on these studies. Although much information has been gained this way, the predictions developed do not include the effect of an active biomass on the mass transfer and flow properties of the culture. It is important to carry out studies on the non-homogeneous fermentation fluids, and develop correlations based on these studies.

On-line measurement in biotechnology: Techniques

Bioprocesses are generally ill controlled. This is due to the fact that the measurement of relevant variables is difficult. Therefore, fundamental knowledge of metabolic interrelations is, at least in vivo, limited. In this article, some of the most important measurement techniques are reviewed in order to provide an evaluation of their current state. Emphasis is given to the underlying principles and on-line capability which allow to judge their importance and potential for exploitation resulting in well (maybe entirely) controlled bioprocesses in the future.

Influence of oxygenation and carbon dioxide on the growth ofRhizobium meliloti in a fermenter

A decrease in dissolved O2 from 90% to 50% saturation in a fermenter adversely affected both blomass production ofRhizobium meliloti ATCC 9930 and viable cell number, although oxygen was never limiting. Lower amounts of dissolved oxygen, or accidental decreases in dissolved oxygen concentration, also caused appreciable acidification of the culture broth, which was the result of CO2 accumulation in the medium. Adding CO2 to the aeration gas mixture affected both biomass production and mean generation time in proportion to the CO2 concentration; the effect on viable cell number was less pronounced.R. meliloti may be considered as a microorganism moderately sensitive to CO2. GoodR. meliloti growth requires, among other things, not only sufficient aeration (oxygenation) but also good ventilation of the CO2 evolved during the fermentation.