Enhancement of protein activity in a recombinant fermentation by optimizing fluid dispersion and initial plasmid copy number distribution

From shake flasks to bioreactors: survival of E. coli cells harboring pGST-hPTH through auto-induction by controlling initial content of yeast extract

A high content of yeast extract in complex media can cause auto-induction of phage T7 RNA polymerase and the consequent expression of recombinant protein in Escherichia coli BL21(DE3) during long-term cultivation. Our study demonstrated that the auto-induction of recombinant protein varied in different vectors harboring heterologous genes. Trx, GST, and their fusion proteins such as GST-human parathyroid hormone (hPTH), expressed by pET32a (+), were easily auto-induced by media containing a high content of yeast extract; however, rtPA was not easily auto-induced when using pET22b (+), although both pET systems were under the control of T7lac promoter. Furthermore, the auto-induction of GST-hPTH may start within 1-2 h after inoculation in bioreactors, which is a deficiency in the scale-up from shake flasks to bioreactors. Our results indicated that too much yeast extract in bioreactor cultivations may be responsible for the early auto-induction of target proteins and consequent loss of cell viability and plasmid instability. To achieve a satisfactory yield, host cells with both high cell viability and plasmid stability were necessary for the starter cultures in shake flasks and pre-induction cultures in bioreactors. This could be achieved simply by controlling the initial content of yeast extract and its subsequent supplementation.

Dispersion optimization to enhance PHB production in fed-batch cultures of Ralstonia eutropha

Despite its many useful properties, microbial production of poly-beta-hydroxybutyrate (PHB) is not yet commercially competitive with synthetic polymers. One reason is inadequate optimization of the fermentation under industrial conditions. In this study, a physiologically reasonable and experimentally validated kinetic model for PHB synthesis by Ralstonia eutropha was incorporated into a dispersion model to simulate a large fed-batch bioreactor. Solutions of the model indicated that cell growth and PHB synthesis were maximum at Peclet numbers (Pe) between 20 and 30, representing limited finite dispersion. At these Peclet numbers, the optimum feed rates also showed lower consumptions of the substrates than at Pe=0. Since complete dispersion was also difficult to achieve in production-scale bioreactors, these results pointed to the possibility of exploiting controlled dispersion for productivity enhancement.

Oscillatory metabolism of Saccharomyces cerevisiae: an overview of mechanisms and models

The budding yeast Saccharomyces cerevisiae displays steady oscillations in continuous cultures under certain conditions. Oscillatory responses are important both metabolically and in process applications. Although much information has become available, a definitive theory to explain and model these oscillations is yet to be formulated. Models of oscillatory cultivation have focussed primarily either on intracellular reactions or on transport processes coupled to substantially lumped intracellular kinetics. This review discusses the development of the models and the directions they provide for a comprehensive model of oscillatory metabolism.

Effect of fluid dispersion on cybernetic control of microbial growth on substitutable substrates

Many fermentation media contain two or more substrates, which a microorganism utilizes for similar purposes. Depending on the conditions prior to and during a fermentation, the substrates may be utilized in succession or simultaneously. Since it is difficult to portray this behavior through mechanistic models, a cybernetic method was proposed earlier. Here the microorganism chooses the mode of substrate utilization that maximizes its own survival, usually expressed by the growth rate. In a fully dispersed bioreactor, simultaneous utilization generates higher growth rates but leads to low biomass concentrations since this utilization pattern is preferred at low concentrations of the substrates. In this study it has been shown that by allowing less than complete dispersion in the broth it is possible to shift from sequential to simultaneous utilization at high concentrations, thereby enabling both high growth rates and large biomass concentrations. This strategy thus allows the natural incomplete dispersion in large bioreactors to be gainfully exploited.

Can imperfections help to improve bioreactor performance?

Pilot-scale and larger bioreactors differ from small laboratory-scale reactors in terms of a greater occurrence of noise and incomplete mixing of the broth. Conventional control tries to induce good mixing and to filter out the noise as completely as possible. As such an 'ideal' operation is difficult to achieve, recent work has tried to exploit the non-ideal features to improve the performance. Using artificial neural networks, the degree of mixing, the extent of filtering of noise and the distribution of plasmid copy number (in a recombinant fermentation) can be controlled effectively on-line. This strategy generates better productivities than well-mixed noise-free operations, which suggests that deviations from ideal behaviour should be gainfully harnessed and not suppressed.