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Rahimzadeh A, Ein-Mozaffari F, Lohi A. Analyzing of hydrodynamic stress and mass transfer requirements of a fermentation process carried out in a coaxial bioreactor: a scale-up study. Bioprocess Biosyst Eng 2024; 47:633-649. [PMID: 38557906 DOI: 10.1007/s00449-024-02990-w] [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: 12/12/2023] [Accepted: 03/04/2024] [Indexed: 04/04/2024]
Abstract
Fluid hydrodynamic stress has a deterministic effect on the morphology of filamentous fungi. Although the coaxial mixer has been recognized as a suitable gas dispersion system for minimizing inhomogeneities within a bioreactor, its performance for achieving enhanced oxygen transfer while operating at a reduced shear environment has not been investigated yet, specifically upon scale-up. Therefore, the influence of the impeller type, aeration rate, and central impeller retrofitting on the efficacy of an abiotic coaxial system containing a shear-thinning fluid was examined. The aim was to assess the hydrodynamic parameters, including stress, mass transfer, bubble size, and gas hold-up, upon conducting a scale-up study. The investigation was conducted through dynamic gassing-in, tomography, and computational fluid dynamics combined with population balance methods. It was observed that the coaxial bioreactor performance was strongly influenced by the agitator type. In addition, coaxial bioreactors are scalable in terms of shear environment and oxygen transfer rate.
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Affiliation(s)
- Ali Rahimzadeh
- Department of Chemical Engineering, Toronto Metropolitan University, 350 Victoria Street, Toronto, ON, M5B 2K3, Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering, Toronto Metropolitan University, 350 Victoria Street, Toronto, ON, M5B 2K3, Canada.
| | - Ali Lohi
- Department of Chemical Engineering, Toronto Metropolitan University, 350 Victoria Street, Toronto, ON, M5B 2K3, Canada
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2
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Kaiser SC, Decaria PN, Seidel S, Eibl D. Scaling‐up of an Insect Cell‐based Virus Production Process in a Novel Single‐use Bioreactor with Flexible Agitation. CHEM-ING-TECH 2022. [DOI: 10.1002/cite.202200103] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Stephan C. Kaiser
- Thermo Scientific BioProduction Group, Single-Use Technology 3311 Leonard Court CA-95054 Santa Clara USA
| | - Paula N. Decaria
- Thermo Scientific BioProduction Group, Single-Use Technology 1325 N 1000 W UT-84321 Logan USA
| | - Stefan Seidel
- ZHAW School of Life Sciences and Facility Management Centre for Biochemical Engineering and Cell Cultivation Technique Grüentalstrasse CH-8810 Wädenswil Switzerland
| | - Dieter Eibl
- ZHAW School of Life Sciences and Facility Management Centre for Biochemical Engineering and Cell Cultivation Technique Grüentalstrasse CH-8810 Wädenswil Switzerland
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Zakrzewski R, Lee K, Lye GJ. Development of a miniature bioreactor model to study the impact of pH and DOT fluctuations on CHO cell culture performance as a tool to understanding heterogeneity effects at large-scale. Biotechnol Prog 2022; 38:e3264. [PMID: 35441833 PMCID: PMC9542549 DOI: 10.1002/btpr.3264] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/27/2022] [Accepted: 04/07/2022] [Indexed: 12/04/2022]
Abstract
Understanding the impact of spatial heterogeneities that are known to occur in large‐scale cell culture bioreactors remains a significant challenge. This work presents a novel methodology for mimicking the effects of pH and dissolved oxygen heterogeneities on Chinese hamster ovary (CHO) cell culture performance and antibody quality characteristics, using an automated miniature bioreactor system. Cultures of 4 different cell lines, expressing 3 IgG molecules and one fusion protein, were exposed to repeated pH and dissolved oxygen tension (DOT) fluctuations between pH 7.0–7.5 and DOT 10%–30%, respectively, for durations of 15, 30, and 60 min. Fluctuations in pH had a minimal impact on growth, productivity, and product quality although some changes in lactate metabolism were observed. DOT fluctuations were found to have a more significant impact; a 35% decrease in cell growth and product titre was observed in the fastest growing cell line tested, while all cell lines exhibited a significant increase in lactate accumulation. Product quality analysis yielded varied results; two cell lines showed an increase in the G0F glycan and decrease in G1F, G2F, and Man5; however, another line showed the opposite trend. The study suggests that the response of CHO cells to the effects of fluctuating culture conditions is cell line specific and that higher growing cell lines are most impacted. The miniature bioreactor system described in this work therefore provides a platform for use during early stage cell culture process development to identify cell lines that may be adversely impacted by the pH and DOT heterogeneities encountered on scale‐up. This experimental data can be combined with computational modeling approaches to predict overall cell culture performance in large‐scale bioreactors.
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Affiliation(s)
- Roman Zakrzewski
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, London, UK
| | - Kenneth Lee
- Cell Culture and Fermentation Science, R&D, AstraZeneca, Franklin Building, Granta Park, Cambridge, UK
| | - Gary J Lye
- The Advanced Centre for Biochemical Engineering, Department of Biochemical Engineering, University College London, London, UK
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Šrom O, Trávníková V, Wutz J, Kuschel M, Unsoeld A, Wucherpfennig T, Šoóš M. Characterization of hydrodynamic stress in ambr250® bioreactor system and its impact on mammalian cell culture. Biochem Eng J 2022. [DOI: 10.1016/j.bej.2021.108240] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
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García-Salas S, Gómez-Montes EO, Ramírez-Sotelo MG, Oliver-Salvador MDC. Shear rate as scale-up criterion of the protein production with enhanced proteolytic activity by phosphate addition in the Jacaratia mexicana cell culture. BIOTECHNOL BIOTEC EQ 2021. [DOI: 10.1080/13102818.2021.1944317] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022] Open
Affiliation(s)
- Sergio García-Salas
- Departamento de Bioingeniería, Unidad Profesional Interdisciplinaria de Biotecnología del Instituto Politécnico Nacional (UPIBI-IPN), Ciudad de México, México
| | - Elías Octavio Gómez-Montes
- Departamento de Biotecnología y Bioingeniería, Centro de Investigación y de Estudios Avanzados del Instituto Politécnico Nacional (CINVESTAV-IPN), Ciudad de México, México
- Departamento de Bioingeniería, Escuela de Ingeniería y Ciencias, Instituto Tecnológico y de Estudios Superiores de Monterrey (ITESM-CEM), Estado de México, México
| | - María Guadalupe Ramírez-Sotelo
- Departamento de Bioingeniería, Unidad Profesional Interdisciplinaria de Biotecnología del Instituto Politécnico Nacional (UPIBI-IPN), Ciudad de México, México
| | - María del Carmen Oliver-Salvador
- Departamento de Bioprocesos, Unidad Profesional Interdisciplinaria de Biotecnología del Instituto Politécnico Nacional (UPIBI-IPN), Ciudad de México, México
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Quintanilla D, Chelius C, Iambamrung S, Nelson S, Thomas D, Gernaey KV, Marten MR. A fast and simple method to estimate relative, hyphal tensile-strength of filamentous fungi used to assess the effect of autophagy. Biotechnol Bioeng 2017; 115:597-605. [PMID: 29135022 DOI: 10.1002/bit.26490] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/09/2017] [Accepted: 11/06/2017] [Indexed: 11/10/2022]
Abstract
Fungal hyphal strength is an important phenotype which can have a profound impact on bioprocess behavior. Until now, there is not an efficient method which allows its characterization. Currently available methods are very time consuming, thus, compromising their applicability in strain selection and process development. To overcome this issue, a method for fast and easy, statistically verified quantification of relative hyphal tensile strength was developed. It involves off-line fragmentation in a high shear mixer followed by quantification of fragment size using laser diffraction. Particle size distribution (PSD) is determined, with analysis time on the order of minutes. Plots of PSD 90th percentile versus time allow estimation of the specific fragmentation rate. This novel method is demonstrated by estimating relative hyphal strength during growth in control conditions and rapamycin-induced autophagy for Aspergillus nidulans (parental strain) and a mutant strain (ΔAnatg8) lacking an important autophagy gene. Both strains were grown in shake flasks and relative hyphal tensile strength was compared. The mutant strain grown in control conditions appears to be weaker than the parental strain, suggesting that Anatg8 may play a role in other processes involving cell wall biosynthesis. Furthermore, rapamycin-induced autophagy resulted in apparently weaker cells even for the mutant strain. These findings confirm the utility of the developed method in strain selection and process development.
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Affiliation(s)
- Daniela Quintanilla
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kgs. Lyngby, Denmark
| | - Cynthia Chelius
- Department of Chemical, Biochemical and Environmental Engineering, University of Maryland Baltimore County (UMBC), Baltimore, Maryland
| | - Sirasa Iambamrung
- Department of Chemical, Biochemical and Environmental Engineering, University of Maryland Baltimore County (UMBC), Baltimore, Maryland
| | - Sidney Nelson
- Department of Chemical, Biochemical and Environmental Engineering, University of Maryland Baltimore County (UMBC), Baltimore, Maryland
| | - Donnel Thomas
- Department of Chemical, Biochemical and Environmental Engineering, University of Maryland Baltimore County (UMBC), Baltimore, Maryland
| | - Krist V Gernaey
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kgs. Lyngby, Denmark
| | - Mark R Marten
- Department of Chemical, Biochemical and Environmental Engineering, University of Maryland Baltimore County (UMBC), Baltimore, Maryland
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Reynoso-Cereceda GI, Garcia-Cabrera RI, Valdez-Cruz NA, Trujillo-Roldán MA. Shaken flasks by resonant acoustic mixing versus orbital mixing: Mass transfer coefficient kLa characterization and Escherichia coli cultures comparison. Biochem Eng J 2016. [DOI: 10.1016/j.bej.2015.10.015] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/15/2023]
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Neunstoecklin B, Stettler M, Solacroup T, Broly H, Morbidelli M, Soos M. Determination of the maximum operating range of hydrodynamic stress in mammalian cell culture. J Biotechnol 2015; 194:100-9. [DOI: 10.1016/j.jbiotec.2014.12.003] [Citation(s) in RCA: 31] [Impact Index Per Article: 3.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2014] [Revised: 11/08/2014] [Accepted: 12/09/2014] [Indexed: 10/24/2022]
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9
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Formenti LR, Nørregaard A, Bolic A, Hernandez DQ, Hagemann T, Heins AL, Larsson H, Mears L, Mauricio-Iglesias M, Krühne U, Gernaey KV. Challenges in industrial fermentation technology research. Biotechnol J 2014; 9:727-38. [PMID: 24846823 DOI: 10.1002/biot.201300236] [Citation(s) in RCA: 54] [Impact Index Per Article: 5.4] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/03/2014] [Revised: 04/01/2014] [Accepted: 04/23/2014] [Indexed: 11/06/2022]
Abstract
Industrial fermentation processes are increasingly popular, and are considered an important technological asset for reducing our dependence on chemicals and products produced from fossil fuels. However, despite their increasing popularity, fermentation processes have not yet reached the same maturity as traditional chemical processes, particularly when it comes to using engineering tools such as mathematical models and optimization techniques. This perspective starts with a brief overview of these engineering tools. However, the main focus is on a description of some of the most important engineering challenges: scaling up and scaling down fermentation processes, the influence of morphology on broth rheology and mass transfer, and establishing novel sensors to measure and control insightful process parameters. The greatest emphasis is on the challenges posed by filamentous fungi, because of their wide applications as cell factories and therefore their relevance in a White Biotechnology context. Computational fluid dynamics (CFD) is introduced as a promising tool that can be used to support the scaling up and scaling down of bioreactors, and for studying mixing and the potential occurrence of gradients in a tank.
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Affiliation(s)
- Luca Riccardo Formenti
- Department of Chemical and Biochemical Engineering, Technical University of Denmark (DTU), Lyngby, Denmark
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Bulnes-Abundis D, Carrillo-Cocom LM, Aráiz-Hernández D, García-Ulloa A, Granados-Pastor M, Sánchez-Arreola PB, Murugappan G, Alvarez MM. A simple eccentric stirred tank mini-bioreactor: mixing characterization and mammalian cell culture experiments. Biotechnol Bioeng 2012; 110:1106-18. [PMID: 23124589 DOI: 10.1002/bit.24780] [Citation(s) in RCA: 19] [Impact Index Per Article: 1.6] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/03/2012] [Revised: 10/19/2012] [Accepted: 10/25/2012] [Indexed: 12/20/2022]
Abstract
In industrial practice, stirred tank bioreactors are the most common mammalian cell culture platform. However, research and screening protocols at the laboratory scale (i.e., 5-100 mL) rely primarily on Petri dishes, culture bottles, or Erlenmeyer flasks. There is a clear need for simple-easy to assemble, easy to use, easy to clean-cell culture mini-bioreactors for lab-scale and/or screening applications. Here, we study the mixing performance and culture adequacy of a 30 mL eccentric stirred tank mini-bioreactor. A detailed mixing characterization of the proposed bioreactor is presented. Laser induced fluorescence (LIF) experiments and computational fluid dynamics (CFD) computations are used to identify the operational conditions required for adequate mixing. Mammalian cell culture experiments were conducted with two different cell models. The specific growth rate and the maximum cell density of Chinese hamster ovary (CHO) cell cultures grown in the mini-bioreactor were comparable to those observed for 6-well culture plates, Erlenmeyer flasks, and 1 L fully instrumented bioreactors. Human hematopoietic stem cells were successfully expanded tenfold in suspension conditions using the eccentric mini-bioreactor system. Our results demonstrate good mixing performance and suggest the practicality and adequacy of the proposed mini-bioreactor.
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Affiliation(s)
- David Bulnes-Abundis
- Centro de Biotecnología-FEMSA, Tecnológico de Monterrey at Monterrey, Ave. Eugenio Garza Sada 2501 Sur, Monterrey, Nuevo León C.P. 64849, México
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Sunya S, Delvigne F, Uribelarrea JL, Molina-Jouve C, Gorret N. Comparison of the transient responses of Escherichia coli to a glucose pulse of various intensities. Appl Microbiol Biotechnol 2012; 95:1021-34. [PMID: 22370947 DOI: 10.1007/s00253-012-3938-y] [Citation(s) in RCA: 25] [Impact Index Per Article: 2.1] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/22/2011] [Revised: 02/01/2012] [Accepted: 02/01/2012] [Indexed: 11/24/2022]
Abstract
Dynamic stimulus-responses of Escherichia coli DPD2085, yciG::LuxCDABE reporter strain, to glucose pulses of different intensities (0.08, 0.4 and 1 g L(-1)) were compared using glucose-limited chemostat cultures at dilution rate close to 0.15 h(-1). After at least five residence times, the steady-state cultures were disturbed by a pulse of glucose, engendering conditions of glucose excess with concomitant oxygen limitation. In all conditions, glucose consumption, acetate and formate accumulations followed a linear relationship with time. The resulting specific uptake and production rates as well as respiratory rates were rapidly increased within the first seconds, which revealed a high ability of E. coli strain to modulate its metabolism to a new environment. For transition from glucose-excess to glucose-limited conditions, the cells rapidly re-established its pseudo-steady state. The dynamics of transient responses at the macroscopic viewpoint were shown to be independent on the glucose pulse intensity in the tested range. On the contrary, the E. coli biosensor yciG::luxCDABE revealed a transcriptional induction of yciG gene promoter depending on the quantities of the glucose added, through in situ and online monitoring of the bioluminescence emitted by the cells. Despite many studies describing the dynamics of the transient response of E. coli to glucose perturbations, it is the first time that a direct comparison is reported, using the same experimental design (strain, medium and experimental set up), to study the impact of the glucose pulse intensity on the dynamics of microbial behaviour regarding growth, respiration and metabolite productions.
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Affiliation(s)
- Sirichai Sunya
- Université de Toulouse, 135 Avenue de Rangueil, Toulouse, France
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12
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López E, Domínguez B, Deive FJ, Sanromán MÁ, Longo MA. Scaling-up the production of thermostable lipolytic enzymes from Thermus aquaticus YT1. Bioprocess Biosyst Eng 2012; 35:1011-22. [DOI: 10.1007/s00449-012-0686-4] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/23/2011] [Accepted: 01/12/2012] [Indexed: 11/24/2022]
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Nienow AW, Nordkvist M, Boulton CA. Scale-down/scale-up studies leading to improved commercial beer fermentation. Biotechnol J 2011; 6:911-25. [PMID: 21744501 DOI: 10.1002/biot.201000414] [Citation(s) in RCA: 16] [Impact Index Per Article: 1.2] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/08/2011] [Revised: 05/20/2011] [Accepted: 05/23/2011] [Indexed: 11/09/2022]
Abstract
Scale-up/scale-down techniques are vital for successful and safe commercial-scale bioprocess design and operation. An example is given in this review of recent studies related to beer production. Work at the bench scale shows that brewing yeast is not compromised by mechanical agitation up to 4.5 W/kg; and that compared with fermentations mixed by CO(2) evolution, agitation ≥ 0.04 W/kg is able to reduce fermentation time by about 20%. Work at the commercial scale in cylindroconical fermenters shows that, without mechanical agitation, most of the yeast sediments into the cone for about 50% of the fermentation time, leading to poor temperature control. Stirrer mixing overcomes these problems and leads to a similar reduction in batch time as the bench-scale tests and greatly reduces its variability, but is difficult to install in extant fermenters. The mixing characteristics of a new jet mixer, a rotary jet mixer, which overcomes these difficulties, are reported, based on pilot-scale studies. This change enables the advantages of stirring to be achieved at the commercial scale without the problems. In addition, more of the fermentable sugars are converted into ethanol. This review shows the effectiveness of scale-up/scale-down studies for improving commercial operations. Suggestions for further studies are made: one concerning the impact of homogenization on the removal of vicinal diketones and the other on the location of bubble formation at the commercial scale.
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Affiliation(s)
- Alvin W Nienow
- Centre for Bioprocess Engineering, University of Birmingham, UK.
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