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Lüchtrath C, Lamping F, Hansen S, Finger M, Magnus J, Büchs J. Diffusion-driven fed-batch fermentation in perforated ring flasks. Biotechnol Lett 2024; 46:571-582. [PMID: 38758336 PMCID: PMC11217090 DOI: 10.1007/s10529-024-03493-0] [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: 01/11/2024] [Revised: 03/05/2024] [Accepted: 04/14/2024] [Indexed: 05/18/2024]
Abstract
PURPOSE Simultaneous membrane-based feeding and monitoring of the oxygen transfer rate shall be introduced to the newly established perforated ring flask, which consists of a cylindrical glass flask with an additional perforated inner glass ring, for rapid bioprocess development. METHODS A 3D-printed adapter was constructed to enable monitoring of the oxygen transfer rate in the perforated ring flasks. Escherichia coli experiments in batch were performed to validate the adapter. Fed-batch experiments with different diffusion rates and feed solutions were performed. RESULTS The adapter and the performed experiments allowed a direct comparison of the perforated ring flasks with Erlenmeyer flasks. In batch cultivations, maximum oxygen transfer capacities of 80 mmol L-1 h-1 were reached with perforated ring flasks, corresponding to a 3.5 times higher capacity than in Erlenmeyer flasks. Fed-batch experiments with a feed reservoir concentration of 500 g glucose L-1 were successfully conducted. Based on the oxygen transfer rate, an ammonium limitation could be observed. By adding 40 g ammonium sulfate L-1 to the feed reservoir, the limitation could be prevented. CONCLUSION The membrane-based feeding, an online monitoring technique, and the perforated ring flask were successfully combined and offer a new and promising tool for screening and process development in biotechnology.
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Affiliation(s)
- Clara Lüchtrath
- AVT-Biochemical Engineering, RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany
| | - Felix Lamping
- AVT-Biochemical Engineering, RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany
| | - Sven Hansen
- Evonik Operations GmbH, Paul-Baumann-Straße 1, 45772, Marl, Germany
| | - Maurice Finger
- AVT-Biochemical Engineering, RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany
| | - Jørgen Magnus
- AVT-Biochemical Engineering, RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany
| | - Jochen Büchs
- AVT-Biochemical Engineering, RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany.
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Su M, Ou Y, Fu J, Huang K, Lei J, Zhu L. Developing an orbitally shaken bioreactor featuring a square vessel wall with a large circular chamfer. J Biotechnol 2024; 392:69-77. [PMID: 38885907 DOI: 10.1016/j.jbiotec.2024.06.014] [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: 01/24/2024] [Revised: 06/02/2024] [Accepted: 06/14/2024] [Indexed: 06/20/2024]
Abstract
The impact of orbitally shaking bioreactors (OSRs) on the biopharmaceutical industry is becoming increasingly important. In the preliminary exploration of the orbitally shaking bioreactor performance, the vessel wall shape has a crucial influence on the mixing and mass transfer in the bioreactor. However, the shape of OSRs still maintains a cylindrical structure, significantly limiting the advantages of the orbital shaking mixing. Therefore, in order to further improve the mixing and mass transfer performance of OSRs, a novel wall shape is proposed in this paper. This novel wall shape consists of cylindrical and square parts and looks like a square tank with a large circular chamfer (STCC), which was found could effectively enhance the efficiency of material mixing and mass transfer theoretically. Based on the same specific volumetric power consumption, a comparative analysis was conducted on the mixing time and oxygen transfer efficiency of OSRs with different shape walls using simulation and experimental methods. The results showed that the OSR with STCC was expected to perform higher mixing and oxygen transfer efficiency than the OSR with cylindrical wall. These findings suggested a promising prospect for the future application of the OSRs with STCC.
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Affiliation(s)
- Mingwu Su
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, Guangdong 518060, China
| | - Yixian Ou
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, Guangdong 518060, China
| | - Jia Fu
- The Second Affiliated Hospital of Heilongjiang University of Traditional Chinese Medicine, No.411 Gogol Street, Nangang District, Harbin, Heilongjiang 150000, China
| | - Kaibin Huang
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, Guangdong 518060, China
| | - Jianguo Lei
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, Guangdong 518060, China.
| | - Likuan Zhu
- Guangdong Provincial Key Laboratory of Micro/Nano Optomechatronics Engineering, College of Mechatronics and Control Engineering, Shenzhen University, Nan-hai Ave 3688, Shenzhen, Guangdong 518060, China.
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Singh VK, Jiménez del Val I, Glassey J, Kavousi F. Integration Approaches to Model Bioreactor Hydrodynamics and Cellular Kinetics for Advancing Bioprocess Optimisation. Bioengineering (Basel) 2024; 11:546. [PMID: 38927782 PMCID: PMC11200465 DOI: 10.3390/bioengineering11060546] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/26/2024] [Revised: 05/17/2024] [Accepted: 05/24/2024] [Indexed: 06/28/2024] Open
Abstract
Large-scale bioprocesses are increasing globally to cater to the larger market demands for biological products. As fermenter volumes increase, the efficiency of mixing decreases, and environmental gradients become more pronounced compared to smaller scales. Consequently, the cells experience gradients in process parameters, which in turn affects the efficiency and profitability of the process. Computational fluid dynamics (CFD) simulations are being widely embraced for their ability to simulate bioprocess performance, facilitate bioprocess upscaling, downsizing, and process optimisation. Recently, CFD approaches have been integrated with dynamic Cell reaction kinetic (CRK) modelling to generate valuable information about the cellular response to fluctuating hydrodynamic parameters inside large production processes. Such coupled approaches have the potential to facilitate informed decision-making in intelligent biomanufacturing, aligning with the principles of "Industry 4.0" concerning digitalisation and automation. In this review, we discuss the benefits of utilising integrated CFD-CRK models and the different approaches to integrating CFD-based bioreactor hydrodynamic models with cellular kinetic models. We also highlight the suitability of different coupling approaches for bioprocess modelling in the purview of associated computational loads.
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Affiliation(s)
- Vishal Kumar Singh
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
| | - Ioscani Jiménez del Val
- School of Chemical & Bioprocess Engineering, University College Dublin, D04 V1W8 Dublin, Ireland;
| | - Jarka Glassey
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
- School of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UK
| | - Fatemeh Kavousi
- Process and Chemical Engineering, School of Engineering and Architecture, University College Cork, T12 K8AF Cork, Ireland;
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Takahashi M, Sawada Y, Aoyagi H. A forced aeration system for microbial culture of multiple shaken vessels suppresses volatilization. Arch Microbiol 2024; 206:246. [PMID: 38704767 DOI: 10.1007/s00203-024-03960-2] [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: 02/17/2024] [Accepted: 04/12/2024] [Indexed: 05/07/2024]
Abstract
Shake-flask culture, an aerobic submerged culture, has been used in various applications involving cell cultivation. However, it is not designed for forced aeration. Hence, this study aimed to develop a small-scale submerged shaking culture system enabling forced aeration into the medium. A forced aeration control system for multiple vessels allows shaking, suppresses volatilization, and is attachable externally to existing shaking tables. Using a specially developed plug, medium volatilization was reduced to less than 10%, even after 45 h of continuous aeration (~ 60 mL/min of dry air) in a 50 mL working volume. Escherichia coli IFO3301 cultivation with aeration was completed within a shorter period than that without aeration, with a 35% reduction in the time-to-reach maximum bacterial concentration (26.5 g-dry cell/L) and a 1.25-fold increase in maximum concentration. The maximum bacterial concentration achieved with aeration was identical to that obtained using the Erlenmeyer flask, with a 65% reduction in the time required to reach it.
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Affiliation(s)
- Masato Takahashi
- Institute of Life and Environmental Sciences, University of Tsukuba, Tsukuba, Ibaraki, 305-8572, Japan
| | - Yoshisuke Sawada
- Iwashiya Bio Science, LLC, 2-18-4, Higashi Shinmachi, Itabashi-ku, Tokyo, 174-0074, Japan
| | - Hideki Aoyagi
- Institute of Life and Environmental Sciences, University of Tsukuba, Tsukuba, Ibaraki, 305-8572, Japan.
- Microbiology Research Center for Sustainability (MiCS), University of Tsukuba, Tsukuba, Ibaraki, 305-8572, Japan.
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Dinter C, Gumprecht A, Menze MA, Azizan A, Niehoff PJ, Hansen S, Büchs J. Validation of computational fluid dynamics of shake flask experiments at moderate viscosity by liquid distributions and volumetric power inputs. Sci Rep 2024; 14:3658. [PMID: 38351095 PMCID: PMC10864319 DOI: 10.1038/s41598-024-53980-7] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/06/2023] [Accepted: 02/07/2024] [Indexed: 02/16/2024] Open
Abstract
Computational fluid dynamics (CFD) has recently become a pivotal tool in the design and scale-up of bioprocesses. While CFD has been extensively utilized for stirred tank reactors (STRs), there exists a relatively limited body of literature focusing on CFD applications for shake flasks, almost exclusively concentrated on fluids at waterlike viscosity. The importance of CFD model validation cannot be overstated. While techniques to elucidate the internal flow field are necessary for model validation in STRs, the liquid distribution, caused by the orbital shaking motion of shake flasks, can be exploited for model validation. An OpenFOAM CFD model for shake flasks has been established. Calculated liquid distributions were compared to suitable, previously published experimental data. Across a broad range of shaking conditions, at waterlike and moderate viscosity (16.7 mPa∙s), the CFD model's liquid distributions align excellently with the experimental data, in terms of overall shape and position of the liquid relative to the direction of the centrifugal force. Additionally, the CFD model was used to calculate the volumetric power input, based on the energy dissipation. Depending on the shaking conditions, the computed volumetric power inputs range from 0.1 to 7 kW/m3 and differed on average by 0.01 kW/m3 from measured literature data.
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Affiliation(s)
- Carl Dinter
- RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany
| | - Andreas Gumprecht
- Evonik Operations GmbH, Rodenbacher Chaussee 4, 63457, Hanau-Wolfgang, Germany
| | | | - Amizon Azizan
- School of Chemical Engineering, College of Engineering, Universiti Teknologi MARA, 40450, Shah Alam, Selangor, Malaysia
| | | | - Sven Hansen
- Evonik Operations GmbH, Paul-Baumann-Straße 1, 45772, Marl, Germany
| | - Jochen Büchs
- RWTH Aachen University, Forckenbeckstraße 51, 52074, Aachen, Germany.
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