Fed-batch cultivation of Saccharomyces cerevisiae in a hyperbaric bioreactor

Use of Pressurized and Airlift Bioreactors for Citric Acid Production by Yarrowia lipolytica from Crude Glycerol

Citric acid production is generally carried out in an aqueous medium in stirred tank reactors (STR), where the solubility of oxygen is low and the oxygen demand of microbial cultures is high. Thus, for this bioprocess, providing adequate oxygen mass transfer rate (OTR) from the gas phase into the aqueous culture medium is the main challenge of bioreactor selection and operation. In this study, citric acid production by Yarrowia lipolytica W29 from crude glycerol, in batch cultures, was performed in two non-conventional bioreactors normally associated with high mass transfer efficiency: a pressurized STR and an airlift bioreactor. Increased OTR was obtained by raising the total air pressure in the pressurized STR and by increasing the aeration rate in the airlift bioreactor. An improvement of 40% in maximum citric acid titer was obtained by raising the air pressure from 1 bar to 2 bar, whereas, in the airlift bioreactor, a 30% improvement was attained by increasing the aeration rate from 1 vvm to 1.5 vvm. Both bioreactor types can be successfully applied for the citric acid production process using alternative ways of improving OTR than increasing mechanical stirring power input, thus leading to important operating saving costs.

CO2-elevated cell-free protein synthesis

Gases are the vital nutrition of all organisms as the precursor of metabolism pathways. As a potential biological process, protein synthesis is inevitably regulated by gas transport and utilization. However, the effect of carbon dioxide (CO₂) present in many metabolic pathways on protein synthesis has not been studied well. In this work, carbon dioxide combined with oxygen was employed for cell-free protein synthesis (CFPS) in the tube-in-tube reactor with precise control of gas concentration. In this in vitro system, gases could directly affect the protein synthesis process without transmembrane transport. Varied concentrations of carbon dioxide (0–1%) and constant oxygen concentration (21%) were employed for CFPS to assess the effects. The cell-free reactions with 0.3% CO₂ and 21% O₂ showed the highest protein yields. The combined effect of CO₂ and O₂ also resulted in relatively high protein expression under high oxygen conditions (0.3% CO₂ and 100% O₂). Moreover, metabolomics assays were performed to gain insight into metabolic changes, which showed that CO₂ slightly improved energy metabolism and redox balance. In particular, the extra supplied CO₂ activated the decarboxylating reactions and removed toxic metabolites to recover the protein synthesis activity. The exploration of CO₂ on protein synthesis could provide guiding implications for basic studies and biomanufacturing.

The effect of growth rate on the production and vitality of non-Saccharomyces wine yeast in aerobic fed-batch culture

Non-Saccharomyces wine yeasts are of increasing importance due to their influence on the organoleptic properties of wine and thus the factors influencing the biomass production of these yeasts, as starter cultures, are of commercial value. Therefore, the effects of growth rates on the biomass yield (Y_x/s) and fermentation performance of non-Saccharomyces yeasts at bench and pilot scale were examined. The fermentative performance and (Y_x/s) were optimised, in aerobic fed-batch cultivations, to produce commercial wine seed cultures of Lachancea thermotolerans Y1240, Issatchenkia orientalis Y1161 and Metschnikowia pulcherrima Y1337. Saccharomyces cerevisiae (Lalvin EC1118) was used as a benchmark. A Crabtree positive response was shown by L. thermotolerans in a molasses-based industrial medium, at growth rates exceeding 0.21 h^-1 (µ_crit), resulting in a Y_x/s of 0.76 g/g at 0.21 h^-1 (46% of µ_max) in the aerobic bioreactor-grown fed-batch culture at bench scale. At pilot scale and 0.133 h^-1 (36% of µ_max), this yeast exhibited ethanol concentrations reaching 10.61 g/l, as a possible result of substrate gradients. Crabtree negative responses were observed for I. orientalis and M. pulcherrima resulting in Y_x/s of 0.83 g/g and 0.68 g/g, respectively, below 32% of µ_max. The Y_x/s of M. pulcherrima, I. orientalis and L. thermotolerans was maximised at growth rates between 0.10 and 0.12 h^-1 and the fermentative capacity of these yeasts was maximised at these lower growth rates.

Effect of increasing oxygen partial pressure on Saccharomyces cerevisiae growth and antioxidant and enzyme productions

This study investigated the impact of oxygen partial pressure on yeast growth. Saccharomyces cerevisiae cells were exposed to various hyperbaric air conditions from 1 bar to 9 bar absolute pressure (A). Batch cultures were grown under continuous airflow in a 750 mL (500 mL culture) bioreactor and monitored through growth rate and specific yields of ethanol and glycerol. In addition, the concentrations of antioxidant metabolites glutathione (reduced state, GSH and oxidized state, GSSG) and the activity of antioxidative enzymes superoxide dismutases (SOD) and catalases (CAT) were monitored. The results demonstrated that the different oxygen partial pressures significantly impacted the key growth parameters monitored. Compared with atmospheric pressure, under 2 to 5 bar (A), yeast cells showed higher growth rates (μ = 0.32 ± 0.01 h^-1) and higher catalase (CAT) concentrations (214 ± 5 mU/g). GSH/GSSG ratio (6.36 ± 0.37) maintained until 6 bar (A) and total SOD (240 ± 5 mU/g) level significantly increased compared with 2 bar (A) until 7 bar (A). Under 6 to 9 bar (A), cell growth was inhibited, and a pressure of 9 bar (A) led to excessive GSSG accumulation (GSH/GSSG = 0.31 ± 0.06). The inhibition of t-SOD (160 ± 3 mU/g) and CAT (62.73 ± 0.2 mU/g) was observed under 9 bar (A). A reference experiment (8 bar (A) N₂ + 1 bar (A) air) confirmed that the observed behaviors were entirely due to O₂. In addition to their utility in biotechnological process design, these results showed that growth impairment was solely due to oxidative stress induced by excessive oxygen pressure. KEY POINTS: • Yeast cells were grown in batch mode under 1 to 9 bar (A) air pressures and up to 5 bar (A) promoted then hindered growth. • The GSH/GSSG ratio was stable up to 5 bar (A) then GSSG accumulated to excess. • Complementary investigations of the activity of SOD and CAT validated growth limitations due to oxidative stress.

Polymer-based controlled-release fed-batch microtiter plate - diminishing the gap between early process development and production conditions

BACKGROUND

Fed-batch conditions are advantageous for industrial cultivations as they avoid unfavorable phenomena appearing in batch cultivations. Those are for example the formation of overflow metabolites, catabolite repression, oxygen limitation or inhibition due to elevated osmotic concentrations. For both, the early bioprocess development and the optimization of existing bioprocesses, small-scale reaction vessels are applied to ensure high throughput, low costs and prompt results. However, most conventional small-scale procedures work in batch operation mode, which stands in contrast to fed-batch conditions in large-scale bioprocesses. Extensive expenditure for installations and operation accompany almost all cultivation systems in the market allowing fed-batch conditions in small-scale. An alternative, more cost efficient enzymatic glucose release system is strongly influenced by environmental conditions. To overcome these issues, this study investigates a polymer-based fed-batch system for controlled substrate release in microtiter plates.

RESULTS

Immobilizing a solid silicone matrix with embedded glucose crystals at the bottom of each well of a microtiter plate is a suitable technique for implementing fed-batch conditions in microtiter plates. The results showed that the glucose release rate depends on the osmotic concentration, the pH and the temperature of the medium. Moreover, the applied nitrogen source proved to influence the glucose release rate. A new developed mathematical tool predicts the glucose release for various media conditions. The two model organisms E. coli and H. polymorpha were cultivated in the fed-batch microtiter plate to investigate the general applicability for microbial systems. Online monitoring of the oxygen transfer rate and offline analysis of substrate, product, biomass and pH confirmed that fed-batch conditions are comparable to large-scale cultivations. Furthermore, due to fed-batch conditions in microtiter plates, product formation could be enhanced by the factor 245 compared to batch cultivations.

CONCLUSIONS

The polymer-based fed-batch microtiter plate represents a sophisticated and cost efficient system to mimic typical industrial fed-batch conditions in small-scale. Thus, a more reliable strain screening and early process development can be performed. A systematical scale-down with low expenditure of work, time and money is possible.

CO2 - Intrinsic Product, Essential Substrate, and Regulatory Trigger of Microbial and Mammalian Production Processes

Carbon dioxide formation mirrors the final carbon oxidation steps of aerobic metabolism in microbial and mammalian cells. As a consequence, CO2/HCO3− dissociation equilibria arise in fermenters by the growing culture. Anaplerotic reactions make use of the abundant CO2/HCO3− levels for refueling citric acid cycle demands and for enabling oxaloacetate-derived products. At the same time, CO₂ is released manifold in metabolic reactions via decarboxylation activity. The levels of extracellular CO2/HCO3− depend on cellular activities and physical constraints such as hydrostatic pressures, aeration, and the efficiency of mixing in large-scale bioreactors. Besides, local CO2/HCO3− levels might also act as metabolic inhibitors or transcriptional effectors triggering regulatory events inside the cells. This review gives an overview about fundamental physicochemical properties of CO2/HCO3− in microbial and mammalian cultures effecting cellular physiology, production processes, metabolic activity, and transcriptional regulation.

New insights on the reorganization of gene transcription in Pseudomonas putida KT2440 at elevated pressure

Background

Elevated pressure, elevated oxygen tension (DOT) and elevated carbon dioxide tension (DCT) are readily encountered at the bottom of large industrial bioreactors and during bioprocesses where pressure is applied for enhancing the oxygen transfer. Yet information about their effect on bacteria and on the gene expression thereof is scarce. To shed light on the cellular functions affected by these specific environmental conditions, the transcriptome of Pseudomonas putida KT2440, a bacterium of great relevance for the production of medium-chain-length polyhydroxyalkanoates, was thoroughly investigated using DNA microarrays.

Results

Very well defined chemostat cultivations were carried out with P. putida to produce high quality RNA samples and ensure that differential gene expression was caused exclusively by changes of pressure, DOT and/or DCT. Cellular stress was detected at 7 bar and elevated DCT in the form of heat shock and oxidative stress-like responses, and indicators of cell envelope perturbations were identified as well.

Globally, gene transcription was not considerably altered when DOT was increased from 40 ± 5 to 235 ± 20% at 7 bar and elevated DCT. Nevertheless, differential transcription was observed for a few genes linked to iron-sulfur cluster assembly, terminal oxidases, glutamate metabolism and arginine deiminase pathway, which shows their particular sensitivity to variations of DOT.

Conclusions

This study provides a comprehensive overview on the changes occurring in the transcriptome of P. putida upon mild variations of pressure, DOT and DCT. Interestingly, whereas the changes of gene transcription were widespread, the cell physiology was hardly affected, which illustrates how efficient reorganization of the gene transcription is for dealing with environmental changes that may otherwise be harmful. Several particularly sensitive cellular functions were identified, which will certainly contribute to the understanding of the mechanisms involved in stress sensing/response and to finding ways of enhancing the stress tolerance of microorganisms.

High hydrostatic pressure and the cell membrane: stress response of Saccharomyces cerevisiae

The brewing and baking yeast Saccharomyces cerevisiae is a useful eukaryotic model of stress response systems whose study could lead to the understanding of stress response mechanisms in other organisms. High hydrostatic pressure (HHP) exerts broad effects upon yeast cells, interfering with cell membranes, cellular architecture, and the processes of polymerization and denaturation of proteins. In this review, we focus on the effect of HHP on the S. cerevisiae cell membrane and describe the main signaling pathways involved in the pressure response.

High cell density cultivation of recombinant yeasts and bacteria under non-pressurized and pressurized conditions in stirred tank bioreactors

This study demonstrates the applicability of pressurized stirred tank bioreactors for oxygen transfer enhancement in aerobic cultivation processes. The specific power input and the reactor pressure was employed as process variable. As model organism Escherichia coli, Arxula adeninivorans, Saccharomyces cerevisiae and Corynebacterium glutamicum were cultivated to high cell densities. By applying specific power inputs of approx. 48kWm(-3) the oxygen transfer rate of a E. coli culture in the non-pressurized stirred tank bioreactor was lifted up to values of 0.51moll(-1)h(-1). When a reactor pressure up to 10bar was applied, the oxygen transfer rate of a pressurized stirred tank bioreactor was lifted up to values of 0.89moll(-1)h(-1). The non-pressurized stirred tank bioreactor was able to support non-oxygen limited growth of cell densities of more than 40gl(-1) cell dry weight (CDW) of E. coli, whereas the pressurized stirred tank bioreactor was able to support non-oxygen limited growth of cell densities up to 225gl(-1) CDW of A. adeninivorans, 89gl(-1) CDW of S. cerevisiae, 226gl(-1) CDW of C. glutamicum and 110gl(-1) CDW of E. coli. Compared to literature data, some of these cell densities are the highest values ever achieved in high cell density cultivation of microorganisms in stirred tank bioreactors. By comparing the specific power inputs as well as the k(L)a values of both systems, it is demonstrated that only the pressure is a scaleable tool for oxygen transfer enhancement in industrial stirred tank bioreactors. Furthermore, it was shown that increased carbon dioxide partial pressures did not remarkably inhibit the growth of the investigated model organisms.

Decalactone production by Yarrowia lipolytica under increased O2 transfer rates

Yarrowia lipolytica converts methyl ricinoleate to gamma-decalactone, a high-value fruity aroma compound. The highest amount of 3-hydroxy-gamma-decalactone produced by the yeast (263 mg l(-1)) occurred by increasing the k(L)a up to 120 h(-1) at atmospheric pressure; above it, its concentration decreased, suggesting a predominance of the activity of 3-hydroxyacyl-CoA dehydrogenase. Cultures were grown under high-pressure, i.e., under increased O(2) solubility, but, although growth was accelerated, gamma-decalactone production decreased. However, by applying 0.5 MPa during growth and biotransformation gave increased concentrations of dec-2-en-4-olide and dec-3-en-4-olide (70 mg l(-1)).

Morphological and physiological changes in Saccharomyces cerevisiae by oxidative stress from hyperbaric air

Increase in air or oxygen pressure in microbial cell cultures can cause oxidative stress and consequently affect cell physiology and morphology. The behaviour of Saccharomyces cerevisiae grown under hyperbaric atmospheres of air and pure oxygen was studied. A limit of 1.0 MPa for the air pressure increase (i.e. 0.21 MPa of oxygen partial pressure) in a fed-batch culture of S. cerevisiae was established. Values of 1.5 MPa air pressure and 0.32 MPa pure oxygen pressure strongly inhibited the metabolic activity and the viability of the cells. Also, morphological changes were observed, especially cell-size distribution and the genealogical age profile. Pressure caused cell compression and an increase in number of aged cells. These effects were attributed to oxygen toxicity since similar results were obtained using air or oxygen, if oxygen partial pressure was equal to or higher than 0.32 MPa. The activity of the antioxidant enzymes, catalase and superoxide dismutase (SOD) (cytosolic and mitochondrial isoformes) indicated that the enzymes have different roles in oxidative stress cell protection, depending on other factors that affect the cell physiological state.

Effect of hyperbaric stress on yeast morphology: study by automated image analysis

The effects of hyperbaric stress on the morphology of Saccharomyces cerevisiae were studied in batch cultures under pressures between 0.1 MPa and 0.6 MPa and different gas compositions (air, oxygen, nitrogen or carbon dioxide), covering aerobic and anaerobic conditions. A method using automatic image analysis for classification of S. cerevisiae cells based on their morphology was developed and applied to experimental data. Information on cell size distribution and bud formation throughout the cell cycle is reported. The results show that the effect of pressure on cell activity strongly depends on the nature of the gas used for pressurization. While nitrogen and air to a maximum of 0.6 MPa of pressure were innocuous to yeast, oxygen and carbon dioxide pressure caused cell inactivation, which was confirmed by the reduction of bud cells with time. Moreover, a decrease in the average cell size was found for cells exposed for 7.5 h to 0.6 MPa CO2.