Scale-up of filamentous organisms from tubes and shake-flasks into stirred vessels

Exploitation of Fungal Biodiversity for Discovery of Novel Antibiotics

Fungi were among the first sources for antibiotics. The discovery and development of the penicillin-type and cephalosporin-type β-lactams and their synthetic versions were transformative in emergence of the modern pharmaceutical industry. They remain some of the most important antibiotics, even 70 years after their discovery. Meanwhile, thousands of fungal metabolites have been discovered, yet these metabolites have only contributed a few additional compounds that have entered clinical development. Substantial expansion in fungal biodiversity assessment along with the availability of modern "-OMICS" technology and revolutionary developments in fungal biotechnology have been made in the last 15 years subsequent to the exit of most of the big Pharma companies from the field of novel antibiotics discovery. Therefore, the timing seems opportune to revisit these fascinating chemically rich organisms as a reservoir of small-molecule templates for lead discovery. This review will describe ongoing interdisciplinary scenarios in which specialists in fungal biology collaborate with chemists, pharmacologists and biochemical and process engineers in order to reveal and make new antibiotics. The utility of a pre-selection process based on phylogenetic data and distribution of secondary metabolite encoding gene cluster will be highlighted. Examples of novel bioactive metabolites from fungi derived from special ecological groups and new phylogenetic lineages will also be discussed.

Determination of Oxygen Solubility in Liquid Media

The present work aimed at determining the oxygen saturation in culture medium used in the production of pigments by Monascus ruber CCT 3802. This estimation allows the correction and the minimization of errors on the specific oxygen uptake rates determination because the conversion of oxygen partial pressure to oxygen concentration requires accurate information on oxygen solubility in experimental incubation media. By adding hydrogen peroxide and then transforming into water and oxygen using catalase, it was possible to determinate the saturation concentration of 7.677 and 6.772 mgO2 L−1 in distilled water and in growth medium, respectively. The determination of these parameters makes possible the minimization of errors on the specific oxygen uptake rates determination, once many studies consider the saturation concentration in distilled water.

The solubilization of potassium-bearing rock powder by Aspergillus niger in small-scale batch fermentations

The fungus Aspergillus niger was cultivated in culture medium with an alkaline ultramafic rock powder to evaluate the solubilization of potassium for biofertilizer production. The assays were carried out with 2 strains (CCT4355 and CCT911) in small-scale batch fermentations using 125, 500, 1000, and 2000 mL Erlenmeyer flasks, with a nominal volume of 40%, and rock powder at 0.4%, shaken at 160 r/min, incubated at 30 degrees C, and sampled every 7 days for 35 days. The amount of soluble K(+), the pH of the culture medium, and the acidity were determined. Both strains solubilized K(+) from the rock powder to the same extent (approximately 62%-70% after 35 days) in the 125 mL flasks; however, the percent solubilization decreased at higher volumetric scales. The results also indicated a difference in strain sensitivity to the increase in volumetric scales in batch fermentation. When filter-sterilized air was injected into the medium, the K(+) percent solubilization obtained after 4 days of cultivation was similar to that obtained after a 28 day period. The acid production by the fungus may be a mechanism of rock solubilization, in spite of the elevation in pH values probably caused by the increasing hydrolysis of the silicates. Both strains of A. niger are recommended for solubilizing potassium from ultramafic rocks, but it is necessary to optimize the oxygen transfer, which seemed to affect the rock solubilization at higher volumetric scales.

Critical analysis of engineering aspects of shaken flask bioreactors

Shaking bioreactors are the most frequently used reaction vessels in biotechnology. Since their inception, shaking bioreactors have been playing a significant role in medicine, agriculture, food, environmental, and industrial research. In spite of their huge practical importance, very little is known about the characteristic properties of shaken cultures from an engineering point of view. In this paper, a critical analysis is presented of the mixing characteristics, aeration, mass and heat transfer, power consumption, and suitability for on-line monitoring and control of various environmental and other operating parameters in aerated and anaerobic/anoxic conditions. Aspects of cell damage due to shear stress generated in shaken flask and loss of sterility due to contamination are also discussed.

The kinetics of the removal of nitrogen and organic matter from parboiled rice effluent by cyanobacteria in a stirred batch reactor

The aim of this research was to evaluate the kinetics of the removal of nitrogen and organic matter from parboiled rice effluent by the cyanobacteria Aphanothece microscopica Nägeli. From the results obtained, it was verified that maximum efficiency for the removal of organic matter expressed as COD and total nitrogen (N-TKN) occurred after 15 h of cultivation, being 83.44% and 72.74, respectively. The scale-up process indicated that the volume of the estimated reactor would be 100.2m(3), containing parboiled rice effluent and biomass.

Scale-up from shake flasks to fermenters in batch and continuous mode withCorynebacterium glutamicum on lactic acid based on oxygen transfer and pH

Scale-up from shake flasks to fermenters has been hampered by the lack of knowledge concerning the influence of operating conditions on mass transfer, hydromechanics, and power input. However, in recent years the properties of shake flasks have been described with empirical models. A practical scale-up strategy for everyday use is introduced for the scale-up of aerobic cultures from shake flasks to fermenters in batch and continuous mode. The strategy is based on empirical correlations of the volumetric mass transfer coefficient (k(L) a) and the pH. The accuracy of the empirical k(L) a correlations and the assumptions required to use these correlations for an arbitrary biological medium are discussed. To determine the optimal pH of the culture medium a simple laboratory method based on titration curves of the medium and a mechanistic pH model, which is solely based on the medium composition, is applied. The effectiveness of the scale-up strategy is demonstrated by comparing the behavior of Corynebacterium glutamicum on lactic acid in shake flasks and fermenters in batch and continuous mode. The maximum growth rate (micro(max) = 0.32 h(-1)) and the oxygen substrate coefficient (Y O2 /S= 0.0174 mol/l) of C. glutamicum on lactic acid were equal for shake flask, fermenter, batch, and continuous cultures. The biomass substrate yield was independent of the scale, but was lower in batch cultures (Y(X/S) = 0.36 g/g) than in continuous cultures (Y(X/S) = 0.45 g/g). The experimental data (biomass, respiration, pH) could be described with a simple biological model combined with a mechanistic pH model.

Hydromechanical stress in shake flasks: Correlation for the maximum local energy dissipation rate

Shake flasks are widely used in biotechnological process research. Bioprocesses for which hydromechanical stress may become the rate controlling parameter include those where oils are applied as carbon sources, biotransformation of compounds with low solubility in the aqueous phase, or processes employing animal, plant, or filamentous microorganisms. In this study, the maximum local energy dissipation rate as the measure for hydromechanical stress is characterized in shake flasks by measuring the maximum stable drop size. The theoretical basis for the method is that the maximum stable drop diameter in a coalescence inhibited liquid/liquid dispersion is only a function of the maximum local energy dissipation rate and not of the dispersing apparatus. The maximum local energy dissipation rate is obtained by comparing the drop diameters in shake flasks to those in a stirred tank reactor. At the same volumetric power consumption, the maximum energy dissipation rate in shake flasks is about 10 times lower than in stirred tank reactors explaining the common observation of considerable differences in the morphology of hydromechanically sensitive cells between these two reactor types. At the same volumetric power consumption, the maximum local energy dissipation rate in baffled and in unbaffled shake flasks is very similar. A correlation is presented to quantify the maximum local energy dissipation rate in shake flasks as a function of the operating conditions. Non-negligible drop viscosity may be considered by known literature correlations. Further, from dispersion experiments a critical Reynolds number of about 60,000 is proposed for turbulent flow in unbaffled shake flasks.

Accelerated design of bioconversion processes using automated microscale processing techniques

Microscale processing techniques are rapidly emerging as a means to increase the speed of bioprocess design and reduce material requirements. Automation of these techniques can reduce labour intensity and enable a wider range of process variables to be examined. This article examines recent research on various individual microscale unit operations including microbial fermentation, bioconversion and product recovery techniques. It also explores the potential of automated whole process sequences operated in microwell formats. The power of the whole process approach is illustrated by reference to a particular bioconversion, namely the Baeyer-Villiger oxidation of bicyclo[3.2.0]hept-2-en-6-one for the production of optically pure lactones.

Introduction to advantages and problems of shaken cultures

Shaking bioreactors are the most frequently used reaction vessels in biotechnology and have been so for many decades. In spite of their large practical importance, very little is known about the characteristic properties of shaken cultures from an engineering point of view. The few publications available contain to some extent contradicting statements and conflicting advice concerning the correct operating conditions of shaking bioreactors. Depending on the investigated microbial system, the engineering parameters may more or less significantly influence the experimental results in a quantitative as well as in a qualitative manner. Unfortunately, these kind of interactions are often overlooked or ignored by scientists. Precise knowledge about the controlling hydrodynamic phenomena in shaking bioreactors and quantitative information about the physical parameters influencing the cultures are needed to assure reproducible and meaningful operating conditions. In this introduction, the state of the art of culturing microorganisms in shaking bioreactors is reviewed and some issues of their practical application in screening and process development projects are addressed.