1
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Zhao J, Muawiya MA, Zhuang Y, Wang G. Developing rational scale-down simulators for mimicking substrate heterogeneities based on cell lifelines in industrial-scale bioreactors. BIORESOURCE TECHNOLOGY 2024; 395:130354. [PMID: 38272147 DOI: 10.1016/j.biortech.2024.130354] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/19/2023] [Revised: 01/17/2024] [Accepted: 01/18/2024] [Indexed: 01/27/2024]
Abstract
The influence of extracellular variations on the cellular metabolism and thereby the process performance at large-scale can be evaluated using the so-called scale-down simulators. Nevertheless, the major challenge is to design an appropriate scale-down simulator, which can accurately mimic the cell lifelines that record the flow paths and experiences of cells circulating in large-scale bioreactors. To address this, a dedicated SDSA (scale-down simulator application) was purposedly developed on the basis of black box model and process reaction model established for Penicillium chrysogenum strain as well as cell lifelines or trajectories information in an industrial-scale fermentor. Guided by the SDSA, the industrial-relevant metabolic regimes for substrate availability, i.e., excess, limitation and starvation, were successfully reproduced at laboratory-scale three-compartment scale-down (SD) system. In addition, such SDSA can also display individual process dynamics in each compartment, and demonstrate how individual factors influence the entire bioprocess performance, thus serving both educational and research purposes.
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Affiliation(s)
- Jiachen Zhao
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, People's Republic of China
| | - Muhammad Alkali Muawiya
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, People's Republic of China
| | - Yingping Zhuang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, People's Republic of China
| | - Guan Wang
- State Key Laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, People's Republic of China.
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2
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Hoang MD, Polte I, Frantzmann L, von den Eichen N, Heins AL, Weuster-Botz D. Impact of mixing insufficiencies on L-phenylalanine production with an Escherichia coli reporter strain in a novel two-compartment bioreactor. Microb Cell Fact 2023; 22:153. [PMID: 37574555 PMCID: PMC10424407 DOI: 10.1186/s12934-023-02165-4] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/01/2023] [Accepted: 08/01/2023] [Indexed: 08/15/2023] Open
Abstract
BACKGROUND The omnipresence of population heterogeneity in industrial bioprocesses originates from prevailing dynamic bioprocess conditions, which promote differences in the expression of cellular characteristics. Despite the awareness, the concrete consequences of this phenomenon remain poorly understood. RESULTS Therefore, for the first time, a L-phenylalanine overproducing Escherichia coli quadruple reporter strain was established for monitoring of general stress response, growth behavior, oxygen limitation and product formation of single cells based on mTagBFP2, mEmerald, CyOFP1, and mCardinal2 expression measured by flow cytometry. This strain was applied for the fed-batch production of L-phenylalanine from glycerol and ammonia in a stirred-tank bioreactor at homogeneous conditions compared to the same process in a novel two-compartment bioreactor. This two-compartment bioreactor consists of a stirred-tank bioreactor with an initial volume of 0.9 L (homogeneous zone) with a coiled flow inverter with a fixed working volume of 0.45 L as a bypass (limitation zone) operated at a mean hydraulic residence time of 102 s. The product formation was similar in both bioreactor setups with maximum L-phenylalanine concentrations of 21.1 ± 0.6 g L-1 demonstrating the consistency of this study's microbial L-phenylalanine production. However, cell growth was vulnerable to repetitive exposure to the dynamically changing conditions in the two-compartment bioreactor with maximum biomass yields reduced by 21%. The functionality of reporter molecules was approved in the stirred-tank bioreactor cultivation, in which expressed fluorescence levels of all four markers were in accordance with respective process state variables. Additional evaluation of the distributions on single-cell level revealed the presence of population heterogeneity in both bioprocesses. Especially for the marker of the general stress response and the product formation, the corresponding histograms were characterized by bimodal shapes and broad distributions. These phenomena were pronounced particularly at the beginning and the end of the fed-batch process. CONCLUSIONS The here shown findings confirm multiple reporter strains to be a noninvasive tool for monitoring cellular characteristics and identifying potential subpopulations in bioprocesses. In combination with experiments in scale-down setups, these can be utilized for a better physiological understanding of bioprocesses and support future scale-up procedures.
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Affiliation(s)
- Manh Dat Hoang
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany
| | - Ingmar Polte
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany
| | - Lukas Frantzmann
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany
| | - Nikolas von den Eichen
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany
| | - Anna-Lena Heins
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany.
| | - Dirk Weuster-Botz
- Chair of Biochemical Engineering, TUM School of Engineering and Design, Technical University of Munich, Boltzmannstr. 15, 85748, Garching, Germany
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3
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Hoang MD, Doan DT, Schmidt M, Kranz H, Kremling A, Heins A. Application of an Escherichia coli triple reporter strain for at-line monitoring of single-cell physiology during L-phenylalanine production. Eng Life Sci 2023; 23:e2100162. [PMID: 36619877 PMCID: PMC9815085 DOI: 10.1002/elsc.202100162] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/03/2021] [Revised: 01/24/2022] [Accepted: 02/07/2022] [Indexed: 01/11/2023] Open
Abstract
Biotechnological production processes are sustainable approaches for the production of biobased components such as amino acids for food and feed industry. Scale-up from ideal lab-scale bioreactors to large-scale processes is often accompanied by loss in productivity. This may be related to population heterogeneities of cells originating from isogenic cultures that arise due to dynamic non-ideal conditions in the bioreactor. To better understand this phenomenon, deeper insights into single-cell physiologies in bioprocesses are mandatory before scale-up. Here, a triple reporter strain (3RP) was developed by chromosomally integrating the fluorescent proteins mEmerald, CyOFP1, and mTagBFP2 into the L-phenylalanine producing Escherichia coli strain FUS4 (pF81kan) to allow monitoring of growth, oxygen availability, and general stress response of the single cells. Functionality of the 3RP was confirmed in well-mixed lab-scale fed-batch processes with glycerol as carbon source in comparison to the strain without fluorescent proteins, leading to no difference in process performance. Fluorescence levels could successfully reflect the course of related process state variables, revealed population heterogeneities during the transition between different process phases and potentially subpopulations that exhibit superior process performance. Furthermore, indications were found for noise in gene expression as regulation strategy against environmental perturbation.
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Affiliation(s)
- Manh Dat Hoang
- Chair of Biochemical EngineeringDepartment of Energy and Process EngineeringTUM School of Engineering and DesignTechnical University of MunichGarchingGermany
| | - Dieu Thi Doan
- Systems BiotechnologyDepartment of Energy and Process EngineeringTUM School of Engineering and DesignTechnical University of MunichGarchingGermany
| | - Marlen Schmidt
- Gen‐H Genetic Engineering Heidelberg GmbHHeidelbergGermany
| | - Harald Kranz
- Gen‐H Genetic Engineering Heidelberg GmbHHeidelbergGermany
| | - Andreas Kremling
- Systems BiotechnologyDepartment of Energy and Process EngineeringTUM School of Engineering and DesignTechnical University of MunichGarchingGermany
| | - Anna‐Lena Heins
- Chair of Biochemical EngineeringDepartment of Energy and Process EngineeringTUM School of Engineering and DesignTechnical University of MunichGarchingGermany
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4
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Mayer F, Cserjan-Puschmann M, Haslinger B, Shpylovyi A, Sam C, Soos M, Hahn R, Striedner G. Computational fluid dynamics simulation improves the design and characterization of a plug-flow-type scale-down reactor for microbial cultivation processes. Biotechnol J 2023; 18:e2200152. [PMID: 36442862 DOI: 10.1002/biot.202200152] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/25/2022] [Revised: 08/03/2022] [Accepted: 09/30/2022] [Indexed: 11/30/2022]
Abstract
The scale-up of bioprocesses remains one of the major obstacles in the biotechnology industry. Scale-down bioreactors have been identified as valuable tools to investigate the heterogeneities observed in large-scale tanks at the laboratory scale. Additionally, computational fluid dynamics (CFD) simulations can be used to gain information about fluid flow in tanks used for production. Here, we present the rational design and comprehensive characterization of a scale-down setup, in which a flexible and modular plug-flow reactor was connected to a stirred-tank bioreactor. With the help of CFD using the realizable k-ε model, the mixing time difference between a 20 and 4000 L bioreactor was evaluated and used as scale-down criterion. CFD simulations using a shear stress transport (SST) k-ω turbulence model were used to characterize the plug-flow reactor in more detail, and the model was verified using experiments. Additionally, the model was used to simulate conditions where experiments technically could not be performed due to sensor limitations. Nevertheless, verification is difficult in this case as well. This was the first time a scale-down setup was tested on high-cell-density Escherichia coli cultivations to produce industrially relevant antigen-binding fragments (Fab). Biomass yield was reduced by 11% and specific product yield was reduced by 20% during the scale-down cultivations. Additionally, the intracellular Fab fraction was increased by using the setup. The flexibility of the introduced scale-down setup in combination with CFD simulations makes it a valuable tool for investigating scale effects at the laboratory scale. More information about the large scale is still necessary to further refine the setup and to speed up bioprocess scale-up in the future.
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Affiliation(s)
- Florian Mayer
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Monika Cserjan-Puschmann
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Benedikt Haslinger
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Anton Shpylovyi
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Christian Sam
- Boehringer Ingelheim RCV GmbH & Co KG, Vienna, Austria
| | - Miroslav Soos
- Department of Chemical Engineering, University of Chemistry and Technology Prague, Praha, Czech Republic
| | - Rainer Hahn
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
| | - Gerald Striedner
- Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Vienna, Austria
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5
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Mayer F, Cserjan-Puschmann M, Haslinger B, Shpylovyi A, Dalik T, Sam C, Hahn R, Striedner G. Strain specific properties of Escherichia coli can prevent non-canonical amino acid misincorporation caused by scale-related process heterogeneities. Microb Cell Fact 2022; 21:170. [PMID: 35999607 PMCID: PMC9396823 DOI: 10.1186/s12934-022-01895-1] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/10/2022] [Accepted: 08/09/2022] [Indexed: 11/10/2022] Open
Abstract
BACKGROUND Escherichia coli is one of the most important hosts for production of recombinant proteins in biopharmaceutical industry. However, when selecting a suitable production strain, it is often not considered that a lot of different sub-species exist, which can differ in their genotypes and phenotypes. Another important development step is the scale-up of bioprocesses with the particular challenge that heterogeneities and gradients occur at production scale. These in turn can affect the production organism and can have negative impact on the process and the product quality. Therefore, researchers developed scale-down reactors, which are used to mimic manufacturing conditions in laboratory scale. The main objectives of this study were to determine the extent to which scale-related process inhomogeneities affect the misincorporation of non-canonical amino acids into the recombinant target protein, which is an important quality attribute, and whether strain specific properties may have an impact. RESULTS We investigated two industrially relevant E. coli strains, BL21(DE3) and HMS174(DE3), which produced an antigen binding fragment (Fab). The cells were cultivated in high cell density fed-batch mode at laboratory scale and under scale-down conditions. We demonstrated that the two host strains differ significantly with respect to norleucine misincorporation into the target protein, especially under heterogeneous cultivation conditions in the scale-down reactor. No norleucine misincorporation was observed in E. coli BL21(DE3) for either cultivation condition. In contrast, norleucine incorporation into HMS174(DE3) was already detectable in the reference process and increased dramatically in scale-down experiments. Norleucine incorporation was not random and certain positions were preferred over others, even though only a single codon exists. Differences in biomass and Fab production between the strains during scale-down cultivations could be observed as well. CONCLUSIONS This study has shown that E. coli BL21(DE3) is much more robust to scale-up effects in terms of norleucine misincorporation than the K12 strain tested. In this respect, BL21(DE3) enables better transferability of results at different scales, simplifies process implementation at production scale, and helps to meet regulatory quality guidelines defined for biopharmaceutical manufacturing.
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Affiliation(s)
- Florian Mayer
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Monika Cserjan-Puschmann
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Benedikt Haslinger
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Anton Shpylovyi
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Thomas Dalik
- Department of Chemistry, Institute of Biochemistry, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Christian Sam
- Boehringer Ingelheim RCV GmbH & Co KG, Dr. Boehringer-Gasse 5-11, 1120, Vienna, Austria
| | - Rainer Hahn
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria
| | - Gerald Striedner
- Christian Doppler Laboratory for Production of Next-Level Biopharmaceuticals in E. Coli, Department of Biotechnology, Institute of Bioprocess Science and Engineering, University of Natural Resources and Life Sciences, Muthgasse 18, 1190, Vienna, Austria.
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6
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Täuber S, Blöbaum L, Steier V, Oldiges M, Grünberger A. Microfluidic single-cell scale-down bioreactors: A proof-of-concept for the growth of Corynebacterium glutamicum at oscillating pH values. Biotechnol Bioeng 2022; 119:3194-3209. [PMID: 35950295 DOI: 10.1002/bit.28208] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/05/2022] [Revised: 06/30/2022] [Accepted: 07/29/2022] [Indexed: 11/07/2022]
Abstract
In large-scale bioreactors, gradients in cultivation parameter such as oxygen, substrate and pH result in fluctuating cell environments. pH fluctuations were identified as a critical parameter for bioprocess performance. Traditionally, scale-down systems at the laboratory scale are used to analyze the effects of fluctuating pH values on strain and thus process performance. Here, we demonstrate the application of dynamic microfluidic single-cell cultivation (dMSCC) as a novel scale-down system for the characterization of Corynebacterium glutamicum growth using oscillating pH conditions as a model stress-factor. A detailed comparison between two-compartment reactor (two-CR) scale-down experiments and dMSCC was performed for one specific pH oscillation between reference pH 7 (~ 8 min) and disturbed pH 6 (~2 min). Similar reductions in growth rates were observed in both systems (dMSCC 21% and two-CR 27%) compared to undisturbed cultivation at pH 7. Afterwards, systematic experiments at symmetric and asymmetric pH oscillations between pH ranges of 4-6 and 8-11 and different intervals from 1 minute to 20 minutes, were performed to demonstrate the unique application range and throughput of the dMSCC system. Finally, the strength of the dMSCC application was demonstrated by mimicking fluctuating environmental conditions of a putative large-scale bioprocesse, which is difficult to conduct using two-CRs. This article is protected by copyright. All rights reserved.
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Affiliation(s)
- Sarah Täuber
- Multiscale Bioengineering, Technical Faculty, Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany.,Center for Biotechnology (CeBiTec), Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany
| | - Luisa Blöbaum
- Multiscale Bioengineering, Technical Faculty, Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany.,Center for Biotechnology (CeBiTec), Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany
| | - Valentin Steier
- Institute of Bio- and Geosciences, Forschungszentrum Jülich GmbH, IBG-1: Biotechnology, Jülich, Germany.,Institute of Biotechnology, RWTH Aachen University, Aachen, Germany
| | - Marco Oldiges
- Institute of Bio- and Geosciences, Forschungszentrum Jülich GmbH, IBG-1: Biotechnology, Jülich, Germany.,Institute of Biotechnology, RWTH Aachen University, Aachen, Germany
| | - Alexander Grünberger
- Multiscale Bioengineering, Technical Faculty, Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany.,Center for Biotechnology (CeBiTec), Bielefeld University, Universitätsstraße 25, 33615, Bielefeld, Germany
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7
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Ho P, Täuber S, Stute B, Grünberger A, von Lieres E. Microfluidic Reproduction of Dynamic Bioreactor Environment Based on Computational Lifelines. FRONTIERS IN CHEMICAL ENGINEERING 2022. [DOI: 10.3389/fceng.2022.826485] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/13/2022] Open
Abstract
The biotechnological production of fine chemicals, proteins and pharmaceuticals is usually hampered by loss of microbial performance during scale-up. This challenge is mainly caused by discrepancies between homogeneous environmental conditions at laboratory scale, where bioprocesses are optimized, and inhomogeneous conditions in large-scale bioreactors, where production takes place. Therefore, to improve strain selection and process development, it is of great interest to characterize these fluctuating conditions at large-scale and to study their effects on microbial cells. In this paper, we demonstrate the potential of computational fluid dynamics (CFD) simulation of large-scale bioreactors combined with dynamic microfluidic single-cell cultivation (dMSCC). Environmental conditions in a 200 L bioreactor were characterized with CFD simulations. Computational lifelines were determined by combining simulated turbulent multiphase flow, mass transport and particle tracing. Glucose availability for Corynebacterium glutamicum cells was determined. The reactor was simulated with average glucose concentrations of 6 g m−3, 10 g m−3 and 16 g m−3. The resulting computational lifelines, discretized into starvation and abundance regimes, were used as feed profiles for the dMSCC to investigate how varying glucose concentration affects cell physiology and growth rate. In this study, each colony in the dMSCC device represents a single cell as it travels through the reactor. Under oscillating conditions reproduced in the dMSCC device, a decrease in growth rate of about 40% was observed compared to continuous supply with the same average glucose availability. The presented approach provides insights into environmental conditions observed by microorganisms in large-scale bioreactors. It also paves the way for an improved understanding of how inhomogeneous environmental conditions influence cellular physiology, growth and production.
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8
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García ÁC, Hauptmann P, Neubauer P. Molecular genetic approaches to decrease the uncontrolled misincorporation of non-canonical branched chain amino acids into recombinant mini-proinsulin expressed in Escherichia coli. Microb Cell Fact 2022; 21:30. [PMID: 35246127 PMCID: PMC8896088 DOI: 10.1186/s12934-022-01756-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/19/2021] [Accepted: 02/09/2022] [Indexed: 05/31/2023] Open
Abstract
The uncontrolled incorporation of non-canonical branched chain amino acids (ncBCAAs) such as norleucine, norvaline and β-methylnorleucine into recombinant proteins in E. coli production processes is a crucial problem in the pharmaceutical industry, since it can lead to the production of altered proteins with non-optimal characteristics. Despite various solutions, to date there are no engineered strains that exhibit a reduced accumulation of these ncBAAs. In this study, novel E. coli K-12 BW25113 strains with exogenous tunable expression of target genes of the BCAA biosynthetic pathway were developed. For this purpose, single gene knock-outs for thrA, ilvA, leuA, ilvIH, ilvBN, ilvGM and ilvC were complemented with plasmids containing the respective genes under control of an arabinose promoter. These clones were screened in a mL-bioreactor system in fed-batch mode under both standard cultivation conditions and with pyruvate pulses, and induction of a min-proinsulin. Screening was performed by comparing the impurity profile of the recombinant mini-proinsulin expressed of each clone with the E. coli BW25113 WT strain, and the most promising clones were cultivated in a 15L Screening showed that up-regulation of ilvC, ilvIH and ilvGM, and downregulation of leuA and ilvBN trigger a reduction of norvaline and norleucine accumulation and misincorporation into mini-proinsulin. The stirred tank bioreactor cultivations confirmed that up-regulation of ilvIH and ilvGM were most effective to reduce the ncBCAA misincorporation. This novel approach for a reduced ncBCAA misincorporation may be solution to this old challenging problem in the large-scale production of human therapeutics.
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Affiliation(s)
| | | | - Peter Neubauer
- Chair of Bioprocess Engineering, Department of Biotechnology, Faculty III Process Sciences, Technische Universität Berlin, 10623, Berlin, Germany.
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9
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Sarkar S, Chowdhury R. Simulation on non-ideal behaviour of plug flow bioreactor based on the growth study of Lactobacillus species. Chem Ind 2021. [DOI: 10.1080/00194506.2021.2008275] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/19/2022]
Affiliation(s)
- Santanu Sarkar
- Environment Research Group, R&D, Tata Steel Ltd., Jamshedpur, India
| | - Ranjana Chowdhury
- Chemical Engineering Department, Jadavpur University, Kolkata, India
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10
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Morris C, Madhavarao CN, Yoon S, Ashraf M. Single in-line biomass probe detects CHO cell growth by capacitance and bacterial contamination by conductivity in bioreactor. Biotechnol J 2021; 16:e2100126. [PMID: 34591352 DOI: 10.1002/biot.202100126] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/09/2021] [Revised: 09/22/2021] [Accepted: 09/27/2021] [Indexed: 11/07/2022]
Abstract
BACKGROUND Real time process data facilitates timely decisions, enables better process control, and can increase quality assurance. Biological drugs (mol. Wt. ≥ 40 kDa) are manufactured using mammalian cells such as Chinese hamster ovary (CHO) cells in bioreactors and have significant risks of contamination during processing. In such processes, in-line monitoring of biomass can provide real-time cell growth profiles and indications of bioreactor health. METHODS An in-line conductivity/capacitance probe (Aber Instruments, Aberystwyth, UK) for monitoring CHO cell growth during fed batch cultures for producing an IgG1 monoclonal antibody was employed. Cell growth was measured in real-time using the capacitance probe (pF cm-1 ) while being compared with off-line measurements using a metabolic analyzer (Nova Biomedical, Waltham, MA, USA). Conductivity measurements (mS cm-1 ) detected variations in the solute concentrations in the bioreactor due to nutrient feed, bicarbonate buffer, and cellular metabolism by-products. RESULTS AND CONCLUSION Abnormal increases in conductivity were found to consistently correspond to bacterial contamination, which was confirmed by orthogonal methods. The contaminated bioreactor runs exhibited sharp increases in conductivity rates hours before dissolved oxygen levels precipitously decreased due to bacterial growth. It is proposed that in-line measurement of conductivity could be employed for early detection of bacterial contaminations. The probe may be adopted in pharmaceutical aseptic aqueous liquid handling processes.
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Affiliation(s)
- Caitlin Morris
- Department of Chemical Engineering, University of Massachusetts, Lowell, Lowell, Massachusetts, USA.,Division of Product Quality Research, Office of Testing and Research, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, Maryland, USA
| | - Chikkathur N Madhavarao
- Division of Product Quality Research, Office of Testing and Research, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, Maryland, USA
| | - Seongkyu Yoon
- Department of Chemical Engineering, University of Massachusetts, Lowell, Lowell, Massachusetts, USA
| | - Muhammad Ashraf
- Division of Product Quality Research, Office of Testing and Research, Office of Pharmaceutical Quality, Center for Drug Evaluation and Research, Food and Drug Administration, Silver Spring, Maryland, USA
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11
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Zelle E, Pfelzer N, Oldiges M, Koch-Koerfges A, Bott M, Nöh K, Wiechert W. An energetic profile of Corynebacterium glutamicum underpinned by measured biomass yield on ATP. Metab Eng 2021; 65:66-78. [PMID: 33722651 DOI: 10.1016/j.ymben.2021.03.006] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/04/2020] [Revised: 02/17/2021] [Accepted: 03/06/2021] [Indexed: 11/17/2022]
Abstract
The supply and usage of energetic cofactors in metabolism is a central concern for systems metabolic engineering, particularly in case of energy intensive products. One of the most important parameters for systems wide balancing of energetic cofactors is the ATP requirement for biomass formation YATP/Biomass. Despite its fundamental importance, YATP/Biomass values for non-fermentative organisms are still rough estimates deduced from theoretical considerations. For the first time, we present an approach for the experimental determination of YATP/Biomass using comparative 13C metabolic flux analysis (13C MFA) of a wild type strain and an ATP synthase knockout mutant. We show that the energetic profile of a cell can then be deduced from a genome wide stoichiometric model and experimental maintenance data. Particularly, the contributions of substrate level phosphorylation (SLP) and electron transport phosphorylation (ETP) to ATP generation become available which enables the overall energetic efficiency of a cell to be characterized. As a model organism, the industrial platform organism Corynebacterium glutamicum is used. C. glutamicum uses a respiratory type of energy metabolism, implying that ATP can be synthesized either by SLP or by ETP with the membrane-bound F1FO-ATP synthase using the proton motive force (pmf) as driving force. The presence of two terminal oxidases, which differ in their proton translocation efficiency by a factor of three, further complicates energy balancing for this organism. By integration of experimental data and network models, we show that in the wild type SLP and ETP contribute equally to ATP generation. Thus, the role of ETP in respiring bacteria may have been overrated in the past. Remarkably, in the genome wide setting 65% of the pmf is actually not used for ATP synthesis. However, it turns out that, compared to other organisms C. glutamicum still uses its energy budget rather efficiently.
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Affiliation(s)
- E Zelle
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - N Pfelzer
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - M Oldiges
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - A Koch-Koerfges
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - M Bott
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - K Nöh
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany
| | - W Wiechert
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, D, 52425, Jülich, Germany.
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12
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Sinner P, Stiegler M, Herwig C, Kager J. Noninvasive online monitoring of Corynebacterium glutamicum fed-batch bioprocesses subject to spent sulfite liquor raw material uncertainty. BIORESOURCE TECHNOLOGY 2021; 321:124395. [PMID: 33285509 DOI: 10.1016/j.biortech.2020.124395] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/28/2020] [Revised: 11/04/2020] [Accepted: 11/05/2020] [Indexed: 06/12/2023]
Abstract
In this study the use of a particle filter algorithm to monitor Corynebacterium glutamicum fed-batch bioprocesses with uncertain raw material input composition is shown. The designed monitoring system consists of a dynamic model describing biomass growth on spent sulfite liquor. Based on particle filtering, model simulations are aligned with continuously and noninvasively measured carbon evolution and oxygen uptake rates, giving an estimate of the most probable culture state. Applied on two validation experiments, culture states were accurately estimated during batch and fed-batch operations with root mean square errors below 1.1 g L-1 for biomass, 0.6 g L-1 for multiple substrate concentrations and 0.01 g g-1 h-1 for biomass specific substrate uptake rates. Additionally, upon fed-batch start uncertain feedstock concentrations were corrected by the estimator without the need of any additional measurements. This provides a solid basis towards a more robust operation of bioprocesses utilizing lignocellulosic side streams.
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Affiliation(s)
- Peter Sinner
- Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, Gumpendorfer Straße 1a, 1060 Vienna, Austria
| | - Marlene Stiegler
- Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, Gumpendorfer Straße 1a, 1060 Vienna, Austria
| | - Christoph Herwig
- Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, Gumpendorfer Straße 1a, 1060 Vienna, Austria
| | - Julian Kager
- Institute of Chemical, Environmental and Bioscience Engineering, Technische Universität Wien, Gumpendorfer Straße 1a, 1060 Vienna, Austria.
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13
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Understanding gradients in industrial bioreactors. Biotechnol Adv 2020; 46:107660. [PMID: 33221379 DOI: 10.1016/j.biotechadv.2020.107660] [Citation(s) in RCA: 31] [Impact Index Per Article: 7.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/09/2020] [Revised: 10/22/2020] [Accepted: 11/14/2020] [Indexed: 01/07/2023]
Abstract
Gradients in industrial bioreactors have attracted substantial research attention since exposure to fluctuating environmental conditions has been shown to lead to changes in the metabolome, transcriptome as well as population heterogeneity in industrially relevant microorganisms. Such changes have also been found to impact key process parameters like the yield on substrate and the productivity. Hence, understanding gradients is important from both the academic and industrial perspectives. In this review the causes of gradients are outlined, along with their impact on microbial physiology. Quantifying the impact of gradients requires a detailed understanding of both fluid flow inside industrial equipment and microbial physiology. This review critically examines approaches used to investigate gradients including large-scale experimental work, computational methods and scale-down approaches. Avenues for future work have been highlighted, particularly the need for further coordinated development of both in silico and experimental tools which can be used to further the current understanding of gradients in industrial equipment.
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14
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Hemmerich J, Labib M, Steffens C, Reich SJ, Weiske M, Baumgart M, Rückert C, Ruwe M, Siebert D, Wendisch VF, Kalinowski J, Wiechert W, Oldiges M. Screening of a genome-reduced Corynebacterium glutamicum strain library for improved heterologous cutinase secretion. Microb Biotechnol 2020; 13:2020-2031. [PMID: 32893457 PMCID: PMC7533341 DOI: 10.1111/1751-7915.13660] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2019] [Revised: 08/14/2020] [Accepted: 08/17/2020] [Indexed: 12/19/2022] Open
Abstract
The construction of microbial platform organisms by means of genome reduction is an ongoing topic in biotechnology. In this study, we investigated whether the deletion of single or multiple gene clusters has a positive effect on the secretion of cutinase from Fusarium solani pisi in the industrial workhorse Corynebacterium glutamicum. A total of 22 genome-reduced strain variants were compared applying two Sec signal peptides from Bacillus subtilis. High-throughput phenotyping using robotics-integrated microbioreactor technology with automated harvesting revealed distinct cutinase secretion performance for a specific combination of signal peptide and genomic deletions. The biomass-specific cutinase yield for strain GRS41_51_NprE was increased by ~ 200%, although the growth rate was reduced by ~ 60%. Importantly, the causative deletions of genomic clusters cg2801-cg2828 and rrnC-cg3298 could not have been inferred a priori. Strikingly, bioreactor fed-batch cultivations at controlled growth rates resulted in a complete reversal of the screening results, with the cutinase yield for strain GRS41_51_NprE dropping by ~ 25% compared to the reference strain. Thus, the choice of bioprocess conditions may turn a 'high-performance' strain from batch screening into a 'low-performance' strain in fed-batch cultivation. In conclusion, future studies are needed in order to understand metabolic adaptations of C. glutamicum to both genomic deletions and different bioprocess conditions.
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Affiliation(s)
- Johannes Hemmerich
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
- Bioeconomy Science Center (BioSC)Forschungszentrum JülichJülich52425Germany
| | - Mohamed Labib
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
| | - Carmen Steffens
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
| | - Sebastian J. Reich
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
- Present address:
Institute of Microbiology and BiotechnologyUlm UniversityUlm89081Germany
| | - Marc Weiske
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
| | - Meike Baumgart
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
| | - Christian Rückert
- Microbial Genomics and BiotechnologyCenter for BiotechnologyBielefeld UniversityBielefeld33615Germany
| | - Matthias Ruwe
- Microbial Genomics and BiotechnologyCenter for BiotechnologyBielefeld UniversityBielefeld33615Germany
| | - Daniel Siebert
- Faculty of Biology, Chair of Genetics of ProkaryotesBielefeld UniversityBielefeld33615Germany
- Present address:
Microbial BiotechnologyCampus Straubing for Biotechnology and SustainabilityTechnical University of MunichStraubing94315Germany
| | - Volker F. Wendisch
- Faculty of Biology, Chair of Genetics of ProkaryotesBielefeld UniversityBielefeld33615Germany
| | - Jörn Kalinowski
- Microbial Genomics and BiotechnologyCenter for BiotechnologyBielefeld UniversityBielefeld33615Germany
| | - Wolfgang Wiechert
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
- Bioeconomy Science Center (BioSC)Forschungszentrum JülichJülich52425Germany
- Computational Systems Biotechnology (AVT.CSB)RWTH Aachen UniversityAachen52074Germany
| | - Marco Oldiges
- Institute of Bio‐ and Geosciences – Biotechnology (IBG‐1)Forschungszentrum Jülich, Institute of Bio‐ and Geosciences ‐ Biotechnology (IBG‐1)Jülich52425Germany
- Bioeconomy Science Center (BioSC)Forschungszentrum JülichJülich52425Germany
- Institute of BiotechnologyRWTH Aachen UniversityAachen52074Germany
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15
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Paul K, Böttinger K, Mitic BM, Scherfler G, Posch C, Behrens D, Huber CG, Herwig C. Development, characterization, and application of a 2-Compartment system to investigate the impact of pH inhomogeneities in large-scale CHO-based processes. Eng Life Sci 2020; 20:368-378. [PMID: 32774209 PMCID: PMC7401239 DOI: 10.1002/elsc.202000009] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/13/2020] [Revised: 04/08/2020] [Accepted: 04/29/2020] [Indexed: 01/05/2023] Open
Abstract
Large-scale bioreactors for the production of monoclonal antibodies reach volumes of up to 25 000 L. With increasing bioreactor size, mixing is however affected negatively, resulting in the formation of gradients throughout the reactor. These gradients can adversely affect process performance at large scale. Since mammalian cells are sensitive to changes in pH, this study investigated the effects of pH gradients on process performance. A 2-Compartment System was established for this purpose to expose only a fraction of the cell population to pH excursions and thereby mimicking a large-scale bioreactor. Cells were exposed to repeated pH amplitudes of 0.4 units (pH 7.3), which resulted in decreased viable cell counts, as well as the inhibition of the lactate metabolic shift. These effects were furthermore accompanied by increased absolute lactate levels. Continuous assessment of molecular attributes of the expressed target protein revealed that subunit assembly or N-glycosylation patterns were only slightly influenced by the pH excursions. The exposure of more cells to the same pH amplitudes further impaired process performance, indicating this is an important factor, which influences the impact of pH inhomogeneity. This knowledge can aid in the design of pH control strategies to minimize the effects of pH inhomogeneity in large-scale bioreactors.
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Affiliation(s)
- Katrin Paul
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
| | - Katharina Böttinger
- Department of BiosciencesBioanalytical Research LabsUniversity of SalzburgSalzburgAustria
- Christian Doppler Laboratory for Innovative Tools for Biosimilar CharacterizationUniversity of SalzburgSalzburgAustria
| | - Bernd M. Mitic
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
| | - Georg Scherfler
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
| | | | | | - Christian G. Huber
- Department of BiosciencesBioanalytical Research LabsUniversity of SalzburgSalzburgAustria
- Christian Doppler Laboratory for Innovative Tools for Biosimilar CharacterizationUniversity of SalzburgSalzburgAustria
| | - Christoph Herwig
- Institute of ChemicalEnvironmental and Bioscience EngineeringTU WienViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesTU WienViennaAustria
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16
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Paul K, Herwig C. Scale-down simulators for mammalian cell culture as tools to access the impact of inhomogeneities occurring in large-scale bioreactors. Eng Life Sci 2020; 20:197-204. [PMID: 32874183 PMCID: PMC7447876 DOI: 10.1002/elsc.201900162] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/08/2019] [Revised: 12/23/2019] [Accepted: 12/27/2019] [Indexed: 12/19/2022] Open
Abstract
During the scale-up of a bioprocess, not all characteristics of the process can be kept constant throughout the different scales. This typically results in increased mixing times with increasing reactor volumes. The poor mixing leads in turn to the formation of concentration gradients throughout the reactor and exposes cells to varying external conditions based on their location in the bioreactor. This can affect process performance and complicate process scale-up. Scale-down simulators, which aim at replicating the large-scale environment, expose the cells to changing environmental conditions. This has the potential to reveal adaptation mechanisms, which cells are using to adjust to rapidly fluctuating environmental conditions and can identify possible root causes for difficulties maintaining similar process performance at different scales. This understanding is of utmost importance in process validation. Additionally, these simulators also have the potential to be used for selecting cells, which are most robust when encountering changing extracellular conditions. The aim of this review is to summarize recent work in this interesting and promising area with the focus on mammalian bioprocesses, since microbial processes have been extensively reviewed.
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Affiliation(s)
- Katrin Paul
- Institute of Chemical, Environmental and Bioscience EngineeringViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesViennaAustria
| | - Christoph Herwig
- Institute of Chemical, Environmental and Bioscience EngineeringViennaAustria
- Christian Doppler Laboratory for Mechanistic and Physiological Methods for Improved BioprocessesViennaAustria
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17
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Morschett H, Jansen R, Neuendorf C, Moch M, Wiechert W, Oldiges M. Parallelized microscale fed-batch cultivation in online-monitored microtiter plates: implications of media composition and feed strategies for process design and performance. J Ind Microbiol Biotechnol 2020; 47:35-47. [PMID: 31673873 PMCID: PMC6971147 DOI: 10.1007/s10295-019-02243-w] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/14/2019] [Accepted: 10/15/2019] [Indexed: 01/10/2023]
Abstract
Limited throughput represents a substantial drawback during bioprocess development. In recent years, several commercial microbioreactor systems have emerged featuring parallelized experimentation with optical monitoring. However, many devices remain limited to batch mode and do not represent the fed-batch strategy typically applied on an industrial scale. A workflow for 32-fold parallelized microscale cultivation of protein secreting Corynebacterium glutamicum in microtiter plates incorporating online monitoring, pH control and feeding was developed and validated. Critical interference of the essential media component protocatechuic acid with pH measurement was revealed, but was effectively resolved by 80% concentration reduction without affecting biological performance. Microfluidic pH control and feeding (pulsed, constant and exponential) were successfully implemented: Whereas pH control improved performance only slightly, feeding revealed a much higher optimization potential. Exponential feeding with µ = 0.1 h-1 resulted in the highest product titers. In contrast, other performance indicators such as biomass-specific or volumetric productivity resulted in different optimal feeding regimes.
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Affiliation(s)
- Holger Morschett
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
| | - Roman Jansen
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
- Institute of Biotechnology, RWTH Aachen University, Aachen, Germany
| | - Christian Neuendorf
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
| | - Matthias Moch
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
| | - Wolfgang Wiechert
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany
- Computational Systems Biotechnology, RWTH Aachen University, Aachen, Germany
| | - Marco Oldiges
- Institute of Bio- and Geosciences, IBG-1: Biotechnology, Forschungszentrum Jülich GmbH, Jülich, Germany.
- Institute of Biotechnology, RWTH Aachen University, Aachen, Germany.
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18
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Pooth V, van Gaalen K, Trenkamp S, Wiechert W, Oldiges M. Comprehensive analysis of metabolic sensitivity of 1,4-butanediol producing Escherichia coli toward substrate and oxygen availability. Biotechnol Prog 2019; 36:e2917. [PMID: 31587523 DOI: 10.1002/btpr.2917] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/11/2019] [Revised: 08/12/2019] [Accepted: 08/28/2019] [Indexed: 12/14/2022]
Abstract
Nowadays, chemical production of 1,4-butanediol is supplemented by biotechnological processes using a genetically modified Escherichia coli strain, which is an industrial showcase of successful application of metabolic engineering. However, large scale bioprocess performance can be affected by presence of physical and chemical gradients in bioreactors which are a consequence of imperfect mixing and limited oxygen transfer. Hence, upscaling comes along with local and time dependent fluctuations of cultivation conditions. This study emphasizes on scale-up related effects of microbial 1,4-butanediol production by comprehensive bioprocess characterization in lab scale. Due to metabolic network constraints 1,4-butanediol formation takes place under oxygen limited microaerobic conditions, which can be hardly realized in large scale bioreactor. The purpose of this study was to assess the extent to which substrate and oxygen availability influence the productivity. It was found, that the substrate specific product yield and the production rate are higher under substrate excess than under substrate limitation. Furthermore, the level of oxygen supply within microaerobic conditions revealed strong effects on product and by-product formation. Under strong oxygen deprivation nearly 30% of the consumed carbon is converted into 1,4-butanediol, whereas an increase in oxygen supply results in 1,4-butanediol reduction of 77%. Strikingly, increasing oxygen availability leads to strong increase of main by-product acetate as well as doubled carbon dioxide formation. The study provides clear evidence that scale-up of microaerobic bioprocesses constitute a substantial challenge. Although oxygen is strictly required for product formation, the data give clear evidence that terms of anaerobic and especially aerobic conditions strongly interfere with 1,4-butanediol production.
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Affiliation(s)
- Viola Pooth
- Forschungszentrum Jülich GmbH, Institute of Bio- and Geosciences, IBG-1: Biotechnology, Jülich, Germany.,RWTH Aachen University, Institute of Biotechnology, Aachen, Germany
| | - Kathrin van Gaalen
- Forschungszentrum Jülich GmbH, Institute of Bio- and Geosciences, IBG-1: Biotechnology, Jülich, Germany
| | | | - Wolfgang Wiechert
- Forschungszentrum Jülich GmbH, Institute of Bio- and Geosciences, IBG-1: Biotechnology, Jülich, Germany.,RWTH Aachen University, Computational Systems Biotechnology (AVT.CSB), Aachen, Germany
| | - Marco Oldiges
- Forschungszentrum Jülich GmbH, Institute of Bio- and Geosciences, IBG-1: Biotechnology, Jülich, Germany.,RWTH Aachen University, Institute of Biotechnology, Aachen, Germany
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19
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Conrady M, Lemoine A, Limberg MH, Oldiges M, Neubauer P, Junne S. Carboxylic acid consumption and production by Corynebacterium glutamicum. Biotechnol Prog 2019; 35:e2804. [PMID: 30851150 DOI: 10.1002/btpr.2804] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/01/2018] [Revised: 03/01/2019] [Accepted: 03/05/2019] [Indexed: 11/07/2022]
Abstract
Corynebacterium glutamicum is well-known as an industrial workhorse, most notably for its use in the bulk production of amino acids in the feed and food sector. Previous studies of the effect of gradients in scale-down reactors with complex media disclosed an accumulation of several carboxylic acids and a parallel decrease of growth and product accumulation. This study, therefore, addresses the impact of carboxylic acids, for example, acetate and l-lactate, on the cultivation of the cadaverine producing strain C. glutamicum DM1945Δact3:Ptuf -ldcCopt and their potential role in scale up related performance losses. A fluctuating power input in shake flask and stirred tank cultivations with mineral salt was applied to mimic discontinuous oxygen availability. Results demonstrate, whenever sufficient oxygen was available, C. glutamicum recovered from previously occurring stressful conditions like an oxygen limiting phase. Reassimilation of acids was detected simultaneously. In cultures, which were supplemented with either acetate or l-lactate, a rapid cometabolization of both acids in presence of glucose was observed, showing conversion rates of 7.8 and 3.8 mmol gcell dry weight -1 hr-1 , respectively. Uptake of these acids was accompanied by increased oxygen consumption. Proteins related to oxidative stress response, glycogen synthesis, and the main carbon metabolism were found in altered concentrations under oscillatory cultivation conditions. (Proteomics data are available via ProteomeXchange with identifier PXD012760). Virtually no impact on growth or product formation was observed. We conclude that the reduced growth and product formation in scale-down cultivations when complex media was used is not caused by the accumulation of carboxylic acids.
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Affiliation(s)
- Marius Conrady
- Department of Biotechnology, Bioprocess Engineering, Technische Universität Berlin, Berlin, Germany
| | - Anja Lemoine
- Department of Biotechnology, Bioprocess Engineering, Technische Universität Berlin, Berlin, Germany
| | - Michael H Limberg
- Research Centre Juelich, IBG-1-Institute of Bio- and Geosciences, Biotechnology, Juelich, Germany.,Department of Molecular Biotechnology, Fraunhofer Institute for Molecular Biology and Applied Ecology (IME), Aachen, Germany
| | - Marco Oldiges
- Research Centre Juelich, IBG-1-Institute of Bio- and Geosciences, Biotechnology, Juelich, Germany
| | - Peter Neubauer
- Department of Biotechnology, Bioprocess Engineering, Technische Universität Berlin, Berlin, Germany
| | - Stefan Junne
- Department of Biotechnology, Bioprocess Engineering, Technische Universität Berlin, Berlin, Germany
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20
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Kaboré AK, Delaunay S, Blanchard F, Guedon E, Fick M, Olmos E. Study and modeling of fluctuating dissolved oxygen concentration impact on Corynebacterium glutamicum growth in a scale-down bioreactor. Process Biochem 2019. [DOI: 10.1016/j.procbio.2018.10.016] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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21
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Hemmerich J, Moch M, Jurischka S, Wiechert W, Freudl R, Oldiges M. Combinatorial impact of Sec signal peptides fromBacillus subtilisand bioprocess conditions on heterologous cutinase secretion byCorynebacterium glutamicum. Biotechnol Bioeng 2018; 116:644-655. [DOI: 10.1002/bit.26873] [Citation(s) in RCA: 13] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/27/2018] [Revised: 09/11/2018] [Accepted: 10/26/2018] [Indexed: 12/12/2022]
Affiliation(s)
- Johannes Hemmerich
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
- Bioeconomy Science Center (BioSC)c/o Forschungszentrum JülichJülich Germany
| | - Matthias Moch
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
| | - Sarah Jurischka
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
- Bioeconomy Science Center (BioSC)c/o Forschungszentrum JülichJülich Germany
| | - Wolfgang Wiechert
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
- Bioeconomy Science Center (BioSC)c/o Forschungszentrum JülichJülich Germany
- Computational Systems Biotechnology (AVT.CSB)RWTH Aachen UniversityAachen Germany
| | - Roland Freudl
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
- Bioeconomy Science Center (BioSC)c/o Forschungszentrum JülichJülich Germany
| | - Marco Oldiges
- Forschungszentrum JülichInstitute of Bio‐ and Geosciences—Biotechnology (IBG‐1)Jülich Germany
- Bioeconomy Science Center (BioSC)c/o Forschungszentrum JülichJülich Germany
- Institute of BiotechnologyRWTH Aachen UniversityAachen Germany
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22
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Cheung CKL, Leksawasdi N, Doran PM. Bioreactor scale-down studies of suspended plant cell cultures. AIChE J 2018. [DOI: 10.1002/aic.16415] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Caleb K. -L. Cheung
- School of Biotechnology and Biomolecular Sciences; University of New South Wales; Sydney NSW Australia
| | - Noppol Leksawasdi
- Bioprocess Research Cluster; School of Agro-Industry, Faculty of Agro-Industry, Chiang Mai University; Chiang Mai Thailand
| | - Pauline M. Doran
- Faculty of Science, Engineering and Technology; Swinburne University of Technology; Melbourne VIC Australia
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23
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Wang G, Zhao J, Haringa C, Tang W, Xia J, Chu J, Zhuang Y, Zhang S, Deshmukh AT, van Gulik W, Heijnen JJ, Noorman HJ. Comparative performance of different scale-down simulators of substrate gradients in Penicillium chrysogenum cultures: the need of a biological systems response analysis. Microb Biotechnol 2018; 11:486-497. [PMID: 29333753 PMCID: PMC5902331 DOI: 10.1111/1751-7915.13046] [Citation(s) in RCA: 23] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/03/2017] [Revised: 12/18/2017] [Accepted: 12/18/2017] [Indexed: 12/22/2022] Open
Abstract
In a 54 m3 large‐scale penicillin fermentor, the cells experience substrate gradient cycles at the timescales of global mixing time about 20–40 s. Here, we used an intermittent feeding regime (IFR) and a two‐compartment reactor (TCR) to mimic these substrate gradients at laboratory‐scale continuous cultures. The IFR was applied to simulate substrate dynamics experienced by the cells at full scale at timescales of tens of seconds to minutes (30 s, 3 min and 6 min), while the TCR was designed to simulate substrate gradients at an applied mean residence time (τc) of 6 min. A biological systems analysis of the response of an industrial high‐yielding P. chrysogenum strain has been performed in these continuous cultures. Compared to an undisturbed continuous feeding regime in a single reactor, the penicillin productivity (qPenG) was reduced in all scale‐down simulators. The dynamic metabolomics data indicated that in the IFRs, the cells accumulated high levels of the central metabolites during the feast phase to actively cope with external substrate deprivation during the famine phase. In contrast, in the TCR system, the storage pool (e.g. mannitol and arabitol) constituted a large contribution of carbon supply in the non‐feed compartment. Further, transcript analysis revealed that all scale‐down simulators gave different expression levels of the glucose/hexose transporter genes and the penicillin gene clusters. The results showed that qPenG did not correlate well with exposure to the substrate regimes (excess, limitation and starvation), but there was a clear inverse relation between qPenG and the intracellular glucose level.
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Affiliation(s)
- Guan Wang
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Junfei Zhao
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Cees Haringa
- Transport Phenomena, Chemical Engineering Department, Delft University of Technology, Delft, The Netherlands
| | - Wenjun Tang
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Jianye Xia
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Ju Chu
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Yingping Zhuang
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | - Siliang Zhang
- State key laboratory of Bioreactor Engineering, East China University of Science and Technology (ECUST), Shanghai, China
| | | | - Walter van Gulik
- Cell Systems Engineering, Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Joseph J Heijnen
- Cell Systems Engineering, Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
| | - Henk J Noorman
- DSM Biotechnology Center, Delft, The Netherlands.,Bio Process Engineering, Department of Biotechnology, Delft University of Technology, Delft, The Netherlands
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Limberg MH, Joachim M, Klein B, Wiechert W, Oldiges M. pH fluctuations imperil the robustness of C. glutamicum to short term oxygen limitation. J Biotechnol 2017; 259:248-260. [DOI: 10.1016/j.jbiotec.2017.08.018] [Citation(s) in RCA: 12] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/07/2017] [Revised: 08/15/2017] [Accepted: 08/16/2017] [Indexed: 11/16/2022]
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Haringa C, Deshmukh AT, Mudde RF, Noorman HJ. Euler-Lagrange analysis towards representative down-scaling of a 22 m 3 aerobic S. cerevisiae fermentation. Chem Eng Sci 2017. [DOI: 10.1016/j.ces.2017.01.014] [Citation(s) in RCA: 56] [Impact Index Per Article: 8.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
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Brunner M, Braun P, Doppler P, Posch C, Behrens D, Herwig C, Fricke J. The impact of pH inhomogeneities on CHO cell physiology and fed-batch process performance - two-compartment scale-down modelling and intracellular pH excursion. Biotechnol J 2017; 12. [DOI: 10.1002/biot.201600633] [Citation(s) in RCA: 27] [Impact Index Per Article: 3.9] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2016] [Revised: 12/17/2016] [Accepted: 01/10/2017] [Indexed: 11/09/2022]
Affiliation(s)
- Matthias Brunner
- Research Division Biochemical Engineering; Institute of Chemical Engineering; Vienna University of Technology; Vienna Austria
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses; Vienna University of Technology; Vienna Austria
| | - Philipp Braun
- Research Division Biochemical Engineering; Institute of Chemical Engineering; Vienna University of Technology; Vienna Austria
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses; Vienna University of Technology; Vienna Austria
| | - Philipp Doppler
- Research Division Biochemical Engineering; Institute of Chemical Engineering; Vienna University of Technology; Vienna Austria
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses; Vienna University of Technology; Vienna Austria
| | | | | | - Christoph Herwig
- Research Division Biochemical Engineering; Institute of Chemical Engineering; Vienna University of Technology; Vienna Austria
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses; Vienna University of Technology; Vienna Austria
| | - Jens Fricke
- Research Division Biochemical Engineering; Institute of Chemical Engineering; Vienna University of Technology; Vienna Austria
- CD Laboratory on Mechanistic and Physiological Methods for Improved Bioprocesses; Vienna University of Technology; Vienna Austria
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A Toolbox of Genetically Encoded FRET-Based Biosensors for Rapid l-Lysine Analysis. SENSORS 2016; 16:s16101604. [PMID: 27690044 PMCID: PMC5087393 DOI: 10.3390/s16101604] [Citation(s) in RCA: 22] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/02/2016] [Revised: 09/15/2016] [Accepted: 09/20/2016] [Indexed: 12/12/2022]
Abstract
Background: The fast development of microbial production strains for basic and fine chemicals is increasingly carried out in small scale cultivation systems to allow for higher throughput. Such parallelized systems create a need for new rapid online detection systems to quantify the respective target compound. In this regard, biosensors, especially genetically encoded Förster resonance energy transfer (FRET)-based biosensors, offer tremendous opportunities. As a proof-of-concept, we have created a toolbox of FRET-based biosensors for the ratiometric determination of l-lysine in fermentation broth. Methods: The sensor toolbox was constructed based on a sensor that consists of an optimized central lysine-/arginine-/ornithine-binding protein (LAO-BP) flanked by two fluorescent proteins (enhanced cyan fluorescent protein (ECFP), Citrine). Further sensor variants with altered affinity and sensitivity were obtained by circular permutation of the binding protein as well as the introduction of flexible and rigid linkers between the fluorescent proteins and the LAO-BP, respectively. Results: The sensor prototype was applied to monitor the extracellular l-lysine concentration of the l-lysine producing Corynebacterium glutamicum (C. glutamicum) strain DM1933 in a BioLector® microscale cultivation device. The results matched well with data obtained by HPLC analysis and the Ninhydrin assay, demonstrating the high potential of FRET-based biosensors for high-throughput microbial bioprocess optimization.
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Haringa C, Tang W, Deshmukh AT, Xia J, Reuss M, Heijnen JJ, Mudde RF, Noorman HJ. Euler-Lagrange computational fluid dynamics for (bio)reactor scale down: An analysis of organism lifelines. Eng Life Sci 2016; 16:652-663. [PMID: 27917102 PMCID: PMC5129516 DOI: 10.1002/elsc.201600061] [Citation(s) in RCA: 76] [Impact Index Per Article: 9.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2016] [Revised: 07/11/2016] [Accepted: 07/18/2016] [Indexed: 12/28/2022] Open
Abstract
The trajectories, referred to as lifelines, of individual microorganisms in an industrial scale fermentor under substrate limiting conditions were studied using an Euler‐Lagrange computational fluid dynamics approach. The metabolic response to substrate concentration variations along these lifelines provides deep insight in the dynamic environment inside a large‐scale fermentor, from the point of view of the microorganisms themselves. We present a novel methodology to evaluate this metabolic response, based on transitions between metabolic “regimes” that can provide a comprehensive statistical insight in the environmental fluctuations experienced by microorganisms inside an industrial bioreactor. These statistics provide the groundwork for the design of representative scale‐down simulators, mimicking substrate variations experimentally. To focus on the methodology we use an industrial fermentation of Penicillium chrysogenum in a simplified representation, dealing with only glucose gradients, single‐phase hydrodynamics, and assuming no limitation in oxygen supply, but reasonably capturing the relevant timescales. Nevertheless, the methodology provides useful insight in the relation between flow and component fluctuation timescales that are expected to hold in physically more thorough simulations. Microorganisms experience substrate fluctuations at timescales of seconds, in the order of magnitude of the global circulation time. Such rapid fluctuations should be replicated in truly industrially representative scale‐down simulators.
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Affiliation(s)
- Cees Haringa
- Transport Phenomena Section Department of Chemical Engineering Delft University of Technology Delft The Netherlands
| | - Wenjun Tang
- State key laboratory of Bioreactor Engineering East China University of Science and Technology (ECUST) Shanghai People's Republic of China
| | | | - Jianye Xia
- State key laboratory of Bioreactor Engineering East China University of Science and Technology (ECUST) Shanghai People's Republic of China
| | - Matthias Reuss
- Stuttgart Research Center Systems Biology (SRCSB) University of Stuttgart Stuttgart Germany
| | - Joseph J Heijnen
- Cell Systems Engineering Department of Biotechnology Delft University of Technology Delft The Netherlands
| | - Robert F Mudde
- Transport Phenomena Section Department of Chemical Engineering Delft University of Technology Delft The Netherlands
| | - Henk J Noorman
- DSM Biotechnology Center Delft The Netherlands; Bio Separation Technology Department of Biotechnology Delft University of Technology Delft The Netherlands
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Löffler M, Simen JD, Jäger G, Schäferhoff K, Freund A, Takors R. Engineering E. coli for large-scale production - Strategies considering ATP expenses and transcriptional responses. Metab Eng 2016; 38:73-85. [PMID: 27378496 DOI: 10.1016/j.ymben.2016.06.008] [Citation(s) in RCA: 60] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/16/2016] [Revised: 06/20/2016] [Accepted: 06/30/2016] [Indexed: 01/18/2023]
Abstract
Microbial producers such as Escherichia coli are evolutionarily trained to adapt to changing substrate availabilities. Being exposed to large-scale production conditions, their complex, multilayered regulatory programs are frequently activated because they face changing substrate supply due to limited mixing. Here, we show that E. coli can adopt both short- and long-term strategies to withstand these stress conditions. Experiments in which glucose availability was changed over a short time scale were performed in a two-compartment bioreactor system. Quick metabolic responses were observed during the first 30s of glucose shortage, and after 70s, fundamental transcriptional programs were initiated. Since cells are fluctuating under simulated large-scale conditions, this scenario represents a continuous on/off switching of about 600 genes. Furthermore, the resulting ATP maintenance demands were increased by about 40-50%, allowing us to conclude that hyper-producing strains could become ATP-limited under large-scale production conditions. Based on the observed transcriptional patterns, we identified a number of candidate gene deletions that may reduce unwanted ATP losses. In summary, we present a theoretical framework that provides biological targets that could be used to engineer novel E. coli strains such that large-scale performance equals laboratory-scale expectations.
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Affiliation(s)
- Michael Löffler
- University of Stuttgart, Institute of Biochemical Engineering, Allmandring 31, 70569 Stuttgart, Germany
| | - Joana Danica Simen
- University of Stuttgart, Institute of Biochemical Engineering, Allmandring 31, 70569 Stuttgart, Germany
| | - Günter Jäger
- University of Tübingen, Institute of Medical Genetics and Applied Genomics, Calwerstr. 7, 72076 Tübingen, Germany
| | - Karin Schäferhoff
- University of Tübingen, Institute of Medical Genetics and Applied Genomics, Calwerstr. 7, 72076 Tübingen, Germany
| | - Andreas Freund
- University of Stuttgart, Institute of Biochemical Engineering, Allmandring 31, 70569 Stuttgart, Germany
| | - Ralf Takors
- University of Stuttgart, Institute of Biochemical Engineering, Allmandring 31, 70569 Stuttgart, Germany.
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