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Flynn J, Breen L, Narayanan S, Butler M. Measurement and control of foam generation in a mammalian cell culture. Biotechnol Prog 2024; 40:e3450. [PMID: 38476025 DOI: 10.1002/btpr.3450] [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] [Revised: 02/13/2024] [Accepted: 02/19/2024] [Indexed: 03/14/2024]
Abstract
Foam is generated in mammalian cell cultures by excessive agitation or gas sparging. This occurs particularly in cultures that generate recombinant proteins at high cell concentrations. Three antifoam agents were tested for their compatibility with antibody-producing Chinese hamster ovary (CHO) cells. One agent (antifoam 204) was completely inhibitory to growth at a concentration of 10 ppm, one agent (antifoam C) showed partial inhibition and a third (antifoam SE-15) showed no inhibition at this concentration. A novel foam image analyzer (LabCam) was used to evaluate two antifoams (C and SE-15) for their ability to dissipate foam generated in cell culture media by enhanced agitation. The presence of antifoam in the media reduced significantly the foam layer that was generated and this was shown to be rapidly dissipated in the presence of 10 ppm SE-15. The antifoams were also tested for foam dissipation in cultures of CHO cells at >106 cells/mL. Supplementation of the cultures with SE-15 resulted in dissipation of foam generated by excessive gas sparging within 2 min. Under equivalent conditions 75% of foam dissipated in the presence of antifoam C, within 2 min but there was a residual foam layer up to 25 min. This study showed the value of an optical monitoring system (LabCam) for measuring foam generation and dissipation in a bioreactor to assess the efficiency of antifoam agents to reduce foam in a bioreactor. This has the potential for use as a control system that could be designed for continuous monitoring and foam control in a mammalian cell bioprocess.
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Affiliation(s)
- James Flynn
- National Institute for Bioprocessing Research and Training (NIBRT), Dublin, Ireland
| | - Laura Breen
- National Institute for Bioprocessing Research and Training (NIBRT), Dublin, Ireland
| | - Shankara Narayanan
- National Institute for Bioprocessing Research and Training (NIBRT), Dublin, Ireland
| | - Michael Butler
- National Institute for Bioprocessing Research and Training (NIBRT), Dublin, Ireland
- School of Chemical and Bioprocess Engineering, University College Dublin (UCD), Dublin 4, Ireland
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Lindeque RM, Woodley JM. Modeling and Experimental Validation of Continuous Biocatalytic Oxidation in Two Continuous Stirred Tank Reactors in Series. Org Process Res Dev 2022. [DOI: 10.1021/acs.oprd.1c00429] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Rowan M. Lindeque
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
| | - John M. Woodley
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
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Lindeque RM, Woodley JM. The Effect of Dissolved Oxygen on Kinetics during Continuous Biocatalytic Oxidations. Org Process Res Dev 2020. [DOI: 10.1021/acs.oprd.0c00140] [Citation(s) in RCA: 14] [Impact Index Per Article: 2.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/11/2023]
Affiliation(s)
- Rowan M. Lindeque
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kgs. Lyngby, 2800, Denmark
| | - John M. Woodley
- Department of Chemical and Biochemical Engineering, Technical University of Denmark, Kgs. Lyngby, 2800, Denmark
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Velugula-Yellela SR, Williams A, Trunfio N, Hsu CJ, Chavez B, Yoon S, Agarabi C. Impact of media and antifoam selection on monoclonal antibody production and quality using a high throughput micro-bioreactor system. Biotechnol Prog 2017; 34:262-270. [PMID: 29086492 PMCID: PMC5821576 DOI: 10.1002/btpr.2575] [Citation(s) in RCA: 20] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/30/2017] [Revised: 09/01/2017] [Indexed: 01/25/2023]
Abstract
Monoclonal antibody production in commercial scale cell culture bioprocessing requires a thorough understanding of the engineering process and components used throughout manufacturing. It is important to identify high impact components early on during the lifecycle of a biotechnology‐derived product. While cell culture media selection is of obvious importance to the health and productivity of mammalian bioreactor operations, other components such as antifoam selection can also play an important role in bioreactor cell culture. Silicone polymer‐based antifoams were known to have negative impacts on cell health, production, and downstream filtration and purification operations. High throughput screening in micro‐scale bioreactors provides an efficient strategy to identify initial operating parameters. Here, we utilized a micro‐scale parallel bioreactor system to study an IgG1 producing CHO cell line, to screen Dynamis, ProCHO5, PowerCHO2, EX‐Cell Advanced, and OptiCHO media, and 204, C, EX‐Cell, SE‐15, and Y‐30 antifoams and their impacts on IgG1 production, cell growth, aggregation, and process control. This study found ProCHO5, EX‐Cell Advanced, and PowerCHO2 media supported strong cellular growth profiles, with an IVCD of 25‐35 × 106 cells‐d/mL, while maintaining specific antibody production (Qp > 2 pg/cell‐d) for our model cell line and a monomer percentage above 94%. Antifoams C, EX‐Cell, and SE‐15 were capable of providing adequate control of foaming while antifoam 204 and Y‐30 noticeably stunted cellular growth. This work highlights the utility of high throughput micro bioreactors and the importance of identifying both positive and negative impacts of media and antifoam selection on a model IgG1 producing CHO cell line. © 2017 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers Biotechnol. Prog., 34:262–270, 2018
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Affiliation(s)
- Sai Rashmika Velugula-Yellela
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD
| | - Abasha Williams
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD
| | - Nicholas Trunfio
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD.,Dept. of Chemical Engineering, University of Massachusetts, Lowell, MA
| | - Chih-Jung Hsu
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD
| | - Brittany Chavez
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD
| | - Seongkyu Yoon
- Dept. of Chemical Engineering, University of Massachusetts, Lowell, MA
| | - Cyrus Agarabi
- U.S. Food and Drug Administration, Center for Drug Evaluation and Research, Office of Product Quality, Office of Biotechnology Products, Division of Biotechnology Review and Research II, Silver Spring, MD
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Nielsen JC, Senne de Oliveira Lino F, Rasmussen TG, Thykær J, Workman CT, Basso TO. Industrial antifoam agents impair ethanol fermentation and induce stress responses in yeast cells. Appl Microbiol Biotechnol 2017; 101:8237-8248. [PMID: 28993899 PMCID: PMC5719808 DOI: 10.1007/s00253-017-8548-2] [Citation(s) in RCA: 9] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/17/2017] [Revised: 09/06/2017] [Accepted: 09/17/2017] [Indexed: 01/08/2023]
Abstract
The Brazilian sugarcane industry constitutes one of the biggest and most efficient ethanol production processes in the world. Brazilian ethanol production utilizes a unique process, which includes cell recycling, acid wash, and non-aseptic conditions. Process characteristics, such as extensive CO2 generation, poor quality of raw materials, and frequent contaminations, all lead to excessive foam formation during fermentations, which is treated with antifoam agents (AFA). In this study, we have investigated the impact of industrial AFA treatments on the physiology and transcriptome of the industrial ethanol strain Saccharomyces cerevisiae CAT-1. The investigated AFA included industrially used AFA acquired from Brazilian ethanol plants and commercially available AFA commonly used in the fermentation literature. In batch fermentations, it was shown that industrial AFA compromised growth rates and glucose uptake rates, while commercial AFA had no effect in concentrations relevant for defoaming purposes. Industrial AFA were further tested in laboratory scale simulations of the Brazilian ethanol production process and proved to decrease cell viability compared to the control, and the effects were intensified with increasing AFA concentrations and exposure time. Transcriptome analysis showed that AFA treatments induced additional stress responses in yeast cells compared to the control, shown by an up-regulation of stress-specific genes and a down-regulation of lipid biosynthesis, especially ergosterol. By documenting the detrimental effects associated with chemical AFA, we highlight the importance of developing innocuous systems for foam control in industrial fermentation processes.
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Affiliation(s)
- Jens Christian Nielsen
- Novozymes Latin America Ltda, 83707-660, Araucária, Brazil
- Department of Biotechnology and Biomedicine, Technical University of Denmark, DK2800, Kgs. Lyngby, Denmark
- Department of Biology and Biological Engineering, Chalmers University of Technology, SE412 96, Gothenburg, Sweden
| | | | | | - Jette Thykær
- Department of Biotechnology and Biomedicine, Technical University of Denmark, DK2800, Kgs. Lyngby, Denmark
| | - Christopher T Workman
- Department of Biotechnology and Biomedicine, Technical University of Denmark, DK2800, Kgs. Lyngby, Denmark.
| | - Thiago Olitta Basso
- Novozymes Latin America Ltda, 83707-660, Araucária, Brazil.
- Department of Chemical Engineering, Polytechnic School, University of São Paulo, 05508-010, São Paulo, Brazil.
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Gélinas P. Aeration and Foam Control in Baker's Yeast Production: Mapping Patents. Compr Rev Food Sci Food Saf 2016; 15:371-391. [PMID: 33371597 DOI: 10.1111/1541-4337.12188] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/09/2015] [Accepted: 12/03/2015] [Indexed: 11/30/2022]
Abstract
A key ingredient in the baking industry, baker's yeast must be produced under strict controlled conditions. High yields of baker's yeast cannot be attained unless a huge quantity of air is injected into fermentation vats. This review of 245 patent specifications shows that inventors have paid much attention to the distribution of fine air bubbles in order to optimize oxygen transfer to the yeast cells. Technical solutions to reduce energy costs associated with aeration are also proposed. Intense aeration caused foaming problems, so mechanical destruction of foam was first proposed until inventions on specific chemical antifoams were patented. In recent years, the development of cheaper and more efficient foam control techniques has remained an issue. Aeration during yeast growth in tanks impairs its fermentative activity in anaerobic bread dough. Since the beginning of the 20th century, massive adoption of air-grown fed-batch baker's yeast probably encouraged sugar addition to stimulate yeast gassing activity in pan bread characterized by high loaf volume, especially those prepared under short dough fermentation conditions.
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Affiliation(s)
- Pierre Gélinas
- the Food Research and Development Centre, Agriculture and Agri-Food Canada, Saint-Hyacinthe, J2 8E3, Quebec, Canada
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