Bubble-free oxygenation by means of hydrophobic porous membranes

Design and evaluation of a 3D-printed, lab-scale perfusion bioreactor for novel biotechnological applications

3D-printing increased in significance for biotechnological research as new applications like lab-on-a-chip systems, cell culture devices or 3D-printed foods were uncovered. Besides mammalian cell culture, only few of those applications focus on the cultivation of microorganisms and none of these make use of the advantages of perfusion systems. One example for applying 3D-printing for bioreactor development is the microbial utilization of alternative substrates derived from lignocellulose, where dilute carbon concentrations and harmful substances present a major challenge. Furthermore, quickly manufactured and affordable 3D-printed bioreactors can accelerate early development phases through parallelization. In this work, a novel perfusion bioreactor system consisting of parts manufactured by fused filament fabrication (FFF) is presented and evaluated. Hydrophilic membranes are used for cell retention to allow the application of dilute substrates. Oxygen supply is provided by membrane diffusion via hydrophobic polytetrafluoroethylene membranes. An exemplary cultivation of Corynebacterium glutamicum ATCC 13032 supports the theoretical design by achieving competitive biomass concentrations of 18.4 g L-1 after 52 h. As a proof-of-concept for cultivation of microorganisms in perfusion mode, the described bioreactor system has application potential for bioconversion of multi-component substrate-streams in a lignocellulose-based bioeconomy, for in-situ product removal or design considerations of future applications for tissue cultures. Furthermore, this work provides a template-based toolbox with instructions for creating reference systems in different application scenarios or tailor-made bioreactor systems.

New developments in online OUR monitoring and its application to animal cell cultures

The increasing demand for biopharmaceuticals produced in mammalian cells has driven the industry to enhance the productivity of bioprocesses through intensification of culture process. Fed-batch and perfusion culturing strategies are considered the most attractive choices, but the application of these processes requires the availability of reliable online measuring systems for the estimation of cell density and metabolic activity. This manuscript reviews the methods (and the devices used) for monitoring of the oxygen consumption, also known as oxygen uptake rate (OUR), since it is a straightforward parameter to estimate viable cell density and the physiological state of cells. Furthermore, as oxygen plays an important role in the cell metabolism, OUR has also been very useful to estimate nutrient consumption, especially the carbon (glucose and glutamine) and nitrogen (glutamine) sources. Three different methods for the measurement of OUR have been developed up to date, being the dynamic method the golden standard, even though DO and pH perturbations generated in the culture during each measurement. For this, many efforts have been focused in developing non-invasive methods, such as global mass balance or stationary liquid mass balance. The low oxygen consumption rates by the cells and the high accuracy required for oxygen concentration measurement in the gas streams (inlet and outlet) have limited the applicability of the global mass balance methodology in mammalian cell cultures. In contrast, stationary liquid mass balance has successfully been implemented showing very similar OUR profiles compared with those obtained with the dynamic method. The huge amount of studies published in the last years evidence that OUR have become a reliable alternative for the monitoring and control of high cell density culturing strategies with very high productivities.

Photobioreactors in Life Support Systems

Life support systems for long-term space missions or extraterrestrial installations have to fulfill major functions such as purification of water and regeneration of atmosphere as well as the generation of food and energy. For almost 60 years ideas for biological life support systems have been collected and various concepts have been developed and tested. Microalgae as photosynthetic organisms have played a major role in most of these concepts. This review deals with the potentials of using eukaryotic microalgae for life support systems and highlights special requirements and frame conditions for designing space photobioreactors especially regarding illumination and aeration. Mono- and dichromatic illumination based on LEDs is a promising alternative for conventional systems and preliminary results yielded higher photoconversion efficiencies (PCE) for dichromatic red/blue illumination than white illumination. Aeration for microgravity conditions should be realized in a bubble-free manner, for example, via membranes. Finally, a novel photobioreactor concept for space application is introduced being parameterized and tested with the microalga Chlamydomonas reinhardtii. This system has already been tested during two parabolic flight campaigns.

Improving bioreactor cultivation conditions for sensitive cell lines by dynamic membrane aeration

Although the importance of animal cell culture for the industrial (large scale) production of pharmaceutical products is continuously increasing, the sensibility of the cells towards their cultivation environment is still a challenging issue. In comparison to microbial cultures, cell cultures which are not protected by a cell wall are much more sensitive to shear stress and foam formation. Reactor design as well as the selection of 'robust' cell lines is particularly important for these circumstances. Nevertheless, even 'sensitive' cell lines are selected for certain pharmaceutical processes due to various reasons. These sensitive cell lines have even higher requirements regarding their cultivation environment. Important characteristics for the corresponding reactor design are a high (volumetric) gas mass transfer coefficient, low volumetric power input, low shear stress, low susceptibility to bio-fouling, the ability to cultivate sticky cells and sufficient mixing properties. Membrane aeration has been a long-known possibility to meet some of these requirements, but has not often been applied in recent years. The reasons lie mainly in low gas mass transfer rates, a limited installable volume-specific membrane surface area, restrictions in scalability and problems with membrane fouling. The dynamic membrane aeration bioreactor aeration is a simple concept for bubble-free oxygen supply of such sensitive cultures. It overcomes limitations and draw-backs of previous systems. Consisting of an oscillating, centrally arranged rotor (stirrer) that is wrapped with silicone membrane tubing, it enables doubling the gas mass transfer at the same shear stress in the investigated cultivation scales of 12, 20, 100, and 200 L. Continuous cultivation at these scales allows the same product output as fed-batch cultivation does at tremendously larger reactor volumes. Apart from introducing this novel technology, the presentation comprises selected cultivation results obtained for blood coagulation factor VIII in continuous mode and a therapeutic monoclonal antibody in fed-batch mode in comparison to reference trials.

Special Engineering Aspects

The specific characteristics of mammalian cells discussed in Chap. 2 require adapted solutions for bioreactor design and operation. Especially, cell damage by shear stress and aeration has to be considered. Therefore this chapter starts with a detailed discussion of shear stress effects on mammalian cells (anchorage-dependent and suspendable cells) in model systems and bioreactors, respectively, and consequences for reactor design. Appropriate oxygen supply is another critical issue, as adapted oxygen supply systems are required. Techniques for immobilization of cells, either grown on microcarriers in suspension culture or within macroporous carriers in fixed bed or fluidized bed reactors, are discussed as well. With respect to the operation of bioreactors, the characteristics of different culture modes (batch, fed-batch, chemostat, perfusion) are introduced and practical examples are given. Finally, concepts for monitoring of bioreactors, including offline and online methods as well as control loops (e.g. O₂, pH), are considered.

Bioreactors for tissue mass culture: Design, characterization, and recent advances

This paper reviews reports on three-dimensional mammalian tissue growth in bioreactors and the corresponding mammalian tissue growth requirements. The needs for nutrient and waste removal of several mammalian tissues are reviewed and compared with the environment of many reactors currently in use such as the continuous stirred tank, the hollow fiber, the Couette-Taylor, the airlift, and the rotating-wall reactors developed by NASA. Many studies conclude that oxygen supply appears to be one of the most important factors limiting tissue growth. Various correlations to describe oxygen mass transfer are presented and discussed with the aim to provide some guidance to design, construct, and test reactors for tissue mass culture. To obtain tissue thickness clinically valuable, dimensionless and other types of analysis tend to point out that diffusive transport will have to be matched with an important convection to bring sufficient oxygen molecular flux to the growing cells located within a tissue mass. As learned from solid-state fermentation and hairy root culture, during the growth of large biomass, heterogeneity (i.e., channeling, temperature gradients, non-uniform cell growth, transfer gradients, etc.) can cause some important problems and these should be addressed in tissue engineering as well. Reactors (along with the scaffolds) should be designed to minimize these issues. The role of the uterus, the reactor built by Nature, is examined, and the environment provided to a growing embryo is reported, yielding possible paths for further reactor developments. Finally, the importance of cell seeding methods is also addressed.

Experimental and theoretical analysis of tubular membrane aeration for Mammalian cell bioreactors

A combination of experimental and theoretical approaches was used to characterize the dynamics of oxygen transfer in a membrane-aerated bioreactor. Pressure profiles along the length of the membrane at varying entrance and exit pressures were determined by actual experimental measurements, unlike most previous studies that have relied solely on theoretical descriptions of the pressure profile in the tubing. The mass transfer coefficient, k(L)a, was also determined under these conditions and was found to be essentially independent of tubing exit pressure. Measurement of the tubing pressure profile coupled with estimation of k(L)a allowed for computation of the oxygen transfer rate (OTR) along the length of the tubing. A mathematical model that incorporated friction pressure loss and losses due to tubing bending was developed to describe the pressure and hence OTR characteristics of membrane-aerated systems. The applicability of the model was verified by testing it on experimentally measured pressure data, and in all cases the model accurately described experimental data. When tubing properties are known, the mathematical model presented in this study allows for a priori estimation of OTR profiles along the length of the tubing. This information is vital for optimal design and scale-up of membrane-aerated bioreactors for mammalian cell culture.

Membrane contactors in the beverage industry for controlling the water gas composition

In the work described here, membrane contactors are used for coupling the removal of species (oxygen and hydrogen sulfide) present in the water with the water carbonation process. We include both experiments and a theoretical study devoted to the analysis of the transport phenomena that occur in the membrane contactor. The main resistance to mass transport was located at the liquid side. Correlations between Sherwood and Reynolds numbers on the shell side that are suitable for the membrane contactor used to carry out our experiments have been determined. In particular, for Re > 1.6, the expression proposed by Yang and Cussler in 1986: Sh = 0.90 Re(0.40) Sc(0.33) describes the behavior of the system; whereas, for Re between 0.03 and 0.3, a new expression is proposed: Sh = 0.435 Re(1.2)Sc(0.33). A comparison with traditional equipment is also furnished. Membrane contactors offer reduced size, CO(2) consumption, and capital costs.

A new method for on-line measurement of the volumetric oxygen uptake rate in membrane aerated animal cell cultures

Oxygen is a key substrate in animal cell metabolism and its consumption is thus a parameter of great interest for bioprocess monitoring and control. A system for measuring it based on an oxygen balance on the liquid phase was developed. The use of a gas-permeable membrane offered the possibility to provide the required quantity of oxygen into the culture, while avoiding problems of foaming or shear stress generally linked to sparging. This aeration system allowed moreover to keep a known and constant k(L)a value through cultures up to 400 h. Oxygen uptake rate (OUR) was measured on-line with a very good accuracy of +/-5%, and the specific OUR for a CHO cell line was determined during batch (growth phase) and continuous culture as, respectively, equal to 2. 85x10(-13) and 2.54x10(-13) mol O(2) cell(-1) h(-1). It was also shown that OUR continuous monitoring gives actually more information about the metabolic state of the culture than the cell concentration itself, especially during transition phases like the end of the growth phase in a batch culture.

Measurement of volumetric (OUR) and determination of specific (qO2) oxygen uptake rates in animal cell cultures

Oxygen is a key substrate in animal cell metabolism. It has been reported that the oxygen uptake rate (OUR) is a good indicator of cellular activity, and even under some conditions, a good indicator of the number of viable cells. The measurement of OUR is difficult due to many different reasons. In particular, the very low specific consumption rate (0.2 x 10(-12) mol cell h-1), the sensitivity of the cells to variations in dissolved oxygen concentration and the difficulty to provide oxygen without damaging the cells are problems which must be taken into account for the development of OUR measurement methods. Different solutions based on an oxygen balance on either the liquid phase or around the entire reactor, and with a variable or stable concentration of dissolved oxygen have been reported. The accuracy of the OUR measurements and the required analytical devices are very different from method to method.

Perfluorochemicals: their applications and benefits to cell culture

The properties of perfluorochemical liquids, particularly their high gas solubility, enables them to be exploited in cell biotechnology. They can facilitate respiratory-gas delivery to prokaryotic and eukaryotic cells in culture; in some systems, they can stimulate production of biomass, yields of commercially important cellular products and, for plant systems, expression of totipotency. The recoverability, and hence recycleability, of perfluorochemicals from aqueous systems makes their routine use a commercially feasible option. This article reviews the applications and beneficial effects of perfluorochemicals in cultured microbial, animal and plant cells, including both aerobic and anaerobic systems.

Perfluorochemicals and cell biotechnology

Perfluorochemical (PFC) liquids have properties, especially high gas solubility, which make these compounds useful in medicine and biotechnology. PFCs are being employed to facilitate respiratory gas supply to both prokaryotic and eukaryotic cells and, in some systems, to improve biomass production and yields of commercially-important cellular products. Animal (including human) and plant cells have also been cultured at the interface between PFC liquids and aqueous culture medium, while fluorocarbon polymers have been employed as gaspermeable membranes in eukaryotic cell cultures. This paper presents an overview of the applications and beneficial effects of PFCs in microbial, animal and plant culture systems. PFCs have been compared with other physical and chemical options for manipulating respiratory gas supply to cultured cells. PFC-facilitated improvements in cell culture technology will have increasingly important biotechnological implications.

Systematic improvement of a chemically-defined protein-free medium for hybridoma growth and monoclonal antibody production

A chemically-defined protein-free medium (FMX-Turbodoma) has been improved for the production of monoclonal IgA antibodies by hybridoma cells, using a systematic method. Cell growth rate, IgA production, activity and molecular weight pattern have been used as optimization criteria. Of potentially important supplements, glucose, glutamine, Pluronic acid F-68 as well as several amino acids had significant beneficial effects. A determination of amino acids profiles via HPLC analysis allowed the formulation of a balanced medium. Unbalanced supplementations of amino acids were found undesirable because of the toxicity of some amino acids at high concentration. Compared with the basal medium, the maximum viable cell and final IgA concentrations in the final version of the protein-free medium were increased by 130% and 700%, respectively, whereas the IgA molecular weight pattern and in vitro activity were not affected. The IgA production was even higher than in a serum-containing medium (RPMI 1640 + 10% FCS) and the price of the protein-free medium is about 20% of this serum-containing medium. This makes such a protein-free medium very convenient for laboratory and large-scale production.