Characterization and feasibility of a miniaturized stirred tank bioreactor to perform E. coli high cell density fed-batch fermentations

Biotechnology Progress

Volumn 28, Issue 1, 2012, Pages 66-75

  Ali, Shaukat ^a   Perez Pardo, Miguel Angel ^a   Aucamp, Jean P ^a   Craig, Alan ^a   Bracewell, Daniel G ^a   Baganz, Frank ^a  

^a UNIVERSITY COLLEGE LONDON   (United Kingdom)

Author keywords

Engineering characterization; Fab fermentation; High cell density; Miniaturized bioreactor; Scale down

Indexed keywords

BIOPROCESS DEVELOPMENT; BIOPROCESSES; COST-EFFICIENT; E. COLI; FED BATCHES; FED-BATCH FERMENTATION; HIGH CELL DENSITY; MANUFACTURABILITY; PILOT SCALE; POWER INPUT; SCALE DOWN; SHEAR SENSITIVITY; SMALL SCALE; SPECIFIC POWER; STIRRED TANK BIOREACTORS; ULTRA SCALE-DOWN; VOLUMETRIC OXYGEN TRANSFER COEFFICIENT;

BIOREACTORS; CELL CULTURE; CENTRIFUGATION; CENTRIFUGES; CHARACTERIZATION; ESCHERICHIA COLI; FERMENTATION; TANKS (CONTAINERS);

BIOCONVERSION;

OXYGEN;

ARTICLE; BIOMASS; BIOREACTOR; EQUIPMENT DESIGN; ESCHERICHIA COLI; FEASIBILITY STUDY; FERMENTATION; GROWTH, DEVELOPMENT AND AGING; KINETICS; METHODOLOGY; MICROBIOLOGY; PILOT STUDY;

BIOMASS; BIOREACTORS; EQUIPMENT DESIGN; ESCHERICHIA COLI; FEASIBILITY STUDIES; FERMENTATION; INDUSTRIAL MICROBIOLOGY; KINETICS; OXYGEN; PILOT PROJECTS;

ESCHERICHIA COLI;

EID: 84856574352     PISSN: 87567938     EISSN: 15206033     Source Type: Journal    
DOI: 10.1002/btpr.708     Document Type: Article

References (41)

1. Pavlou AK, Reichert JM. Recombinant protein therapeutics-success rates, market trends and values to 2010. Nat Biotechnol. 2004; 22: 1513-1519.
2. Read EK, Part JT, Shah RB, Riley BS, Brorson KA, Rathore AS. Process analytical technology (PAT) for biopharmaceutical products. I. Concepts and applications. Biotechnol Bioeng. 2009; 105: 276-284.
3. Perez-Pardo MA, Ali S, Balasundaram B, Mannall GJ, Baganz F, Bracewell DG. Assessment of the manufacturability of E.coli high cell density fermentations. Biotechnol Prog. DOI: 10.1002/btpr.708.
4. Humphrey A. Shake flask to fermentor: what have we learned? Biotechnol Prog. 1998; 1: 3-7.
5. Büchs J. Introduction to the advantages and problems of shaken cultures. Biochem Eng J. 2000; 7: 91-98.
6. Maier U, Losen M, Büchs J. Advances in understanding and modeling the gas-liquid mass transfer in shake flasks. Biochem Eng J. 2004; 17: 155-167.
7. Gupta A, Rao G. A study of oxygen transfer in shake flasks using a non-invasive oxygen sensor. Biotechnol Bioeng. 2003; 84: 351-358.
8. Hermann R, Walther N, Maier U, Büchs J. Optical method for the determination of the oxygen-transfer capacity of small bioreactors based on sulfite oxidation. Biotechnol Bioeng. 2001; 74: 355-363.
9. Elmahdi I, Baganz F, Dixon K, Harrop T, Sugden D, Lye GJ. pH control in microwell fermentations of S. erythraea CA340: influence on biomass growth kinetics and erythromycin biosynthesis. Biochem Eng J. 2003; 16: 299-310.
10. Kensy F, Zimmermann HF, Knabben I, Anderlei T, Trauthwein H, Dingerdissen U, Büchs J. Oxygen transfer phenomena in 48-well microtiter plates: determination by optical monitoring of sulfite oxidation and verification by real-time measurement during microbial growth. Biotechnol Bioeng. 2005; 89: 699-708.
11. Panula-Perälä J, Šiurkus J, Vasala A, Wilmanowski R, Casteleijn MG, Neubauer P. Enzyme controlled glucose auto-delivery for high cell density cultivations in microplates and shake flasks. Microb Cell Fact. 2008; 7: 31.
12. Gill NK, Appleton M, Baganz F, Lye GJ. Design and characterisation of a miniature stirred bioreactor system for parallel microbial fermentations. Biochem Eng J. 2008; 39: 164-176.
13. Betts JI, Doig SD, Baganz F. Characterization and application of a miniature 10 mL stirred-tank bioreactor, showing scale-down equivalence with a conventional 7 L reactor. Biotechnol Prog. 2006; 22: 681-688.
14. Kusterer A, Krause C, Kaufmann K, Arnold M, Weuster-Botz D. Fully automated single-use stirred-tank bioreactors for parallel microbial cultivations. Bioproc Biosyst Eng. 2008; 31: 207-215.
15. Lamping SR, Zhanga H, Allenb B, Ayazi Shamlou P. Design of a prototype miniature bioreactor for high throughput automated bioprocessing. Chem Eng Sci. 2003; 58: 747-758.
16. Krause M, Ukkonen K, Haataja T, Ruottinen M, Glumoff T, Neubauer A, Neubauer P, Vasala A. A novel fed-batch based cultivation method provides high cell-density and improves yield of soluble recombinant proteins in shaken cultures. Microb Cell Fact. 2010; 9: 11
17. Bowering LC. Microbial systems for the manufacture of therapeutic antibody fragments. Bioprocess Intl. 2004; 2: 40-47.
18. Gill NK, Appleton M, Baganz F, Lye GJ. Quantification of power consumption and oxygen transfer characteristics of a stirred miniature bioreactor for predictive fermentation scale-up. Biotechnol Bioeng. 2008; 100: 1144-1155.
19. Arbabi-Ghahroudi M, Tanha J, Mackenzie R. Prokaryotic expression of antibodies. Cancer Metastasis Rev. 2004; 24: 501-519.
20. Bowering LC, Bracewell DG, Keshavarz-Moore E, Hoare M, Weir ANC. Comparison of techniques for monitoring antibody fragment production in E. coli fermentation cultures. Biotechnol Prog. 2002; 18: 1431-1438.
21. Garcia-Arrazola R, Dawson P, Buchanan I, Doyle B, Fearn T, Titchener-Hooker NJ, Baganz F. Evaluation of the effects and interactions of mixing and oxygen transfer on the production of Fab' antibody fragments in Escherichia coli fermentation with gas blending. Bioprocess Biosyst Eng. 2005; 27: 365-374.
22. Enfors SO, Jahic M, Rozkov A, Xu B, Hecker M, Jurgen B, Kruger E, Schweder T, Hamer G, O'Beirne D, Noisommit-Rizzi N, Reuss M, Boon L, Hewitt C, McFarlane C, Nienow A, Fuchs L, Kovacs T, Revstedt J, Tragardh C, Friberg PC, Hjertager B, Blomsten G, Skogman H, Hjort S, Hoeks F, Lin HY, Neubauer P, Van der Lans R, Luyben K, Vrabel P, Manelius A. Physiological responses to mixing in large bioreactors. J Biotechnol. 2001; 85: 175-185.
23. Onyeaka H, Nienow AW, Hewitt CJ. Further studies related to the scale-up of high cell density Escherichia coli fed-batch fermentations: the additional effect of a changing microenvironment when using aqueous ammonia to control pH. Biotechnol Bioeng. 2003; 84: 474-484.
24. Boychyn, M, Yim SSS, Ayazi Shamlou P, Bulmer M, More J, Hoare M. Characterization of flow intensity in continuous centrifuges for the development of laboratory mimics. Chem Eng Sci. 2001; 56: 4759-4770.
25. Hughmark G. Power requirements and interfacial area in gas-liquid turbine agitated systems. Ind Eng Chem Proc DD. 1980; 19: 638-641.
26. Warmoeskerken MMCG, Smith JM. Impeller loading in multi-turbine vessels. 2nd International Conference on Bioreactor Fluid Dynamics. Cambridge; 1988.
27. Cui YQ, Van der Lans RGJM, Luyben KC. Local power uptake in gas-liquid systems with single and multiple Rushton turbines. Chem Eng Sci. 1996; 51: 2631-2636.
28. Tustian AD, Salte H, Willoughby N, Hassan I, Rose M, Baganz F, Hoare M, Titchener-Hooker NJ. Adapted ultra scale-down approach for predicting the centrifugal separation behaviour of high cell density cultures. Biotechnol Prog. 2007; 23: 1404-1410.
29. Hutchinson N, Bingham N, Murrell N, Farid S, Hoare M. Shear stress analysis of mammalian cell suspensions for prediction of industrial centrifugation and its verification. Biotechnol Bioeng. 2006; 95: 483-491.
30. Tait AS, Aucamp JP, Bugeon A, Hoare M. Ultra scale down prediction using microwell technology of the industrial scale clarification characteristics by centrifugation of mammalian cell broths. Biotechnol Bioeng. 2009; 104: 321-331.
31. Balasundaram B, Nesbeth D, Ward JM, Keshavarz-Moore E, Bracewell DG. Step change in the efficiency of centrifugation through cell engineering: coexpression of Staphylococcal nuclease to reduce the viscosity of the bioprocess feedstock. Biotechnol Bioeng. 2009; 104: 134-142.
32. Hortsch R, Stratmann A, Weuster-Botz D. New millilitre-scale stirred tank bioreactors for the cultivation of mycelium forming microorganisms. Biotechnol Bioeng. 2010; 106: 443-451.
33. Nienow AW, Wisdom DJ, Middleton JC. Effect of scale and geometry on flooding, recirculation and power in stirred vessels. Proceedings of the 2nd European Conference on Mixing. BHRA Cambridge, UK; 1977:(F1) 1-16.
34. Bujalski W, Nienow AW, Chatwin S, Cooke M. The dependency on scale of power numbers of Rushton disc turbines. Chem Eng Sci. 1987; 42: 317-326.
35. Chapman CM, Nienow AW, Cooke M, Middleton JC. Particle-gas-liquid mixing in stirred vessels. I. Particle liquid mixing. Chem Eng Res Des. 1983; 61: 71-81.
36. Hudcova V, Machon V, Nienow AW. Gas-liquid dispersion with dual Rushton turbine impellers. Biotechnol Bioeng. 1989; 34: 617-628.
37. Paglianti A, Takenaka K, Bujalski W. Simple model for power consumption in aerated vessels stirred by Rushton disc turbines. AIChE J. 2001; 47: 2673-2683.
38. Shukla VB, Parasu Veera U, Kulkarni PR, Pandit AB. Scale-up of biotransformation process in stirred tank reactor using dual impeller bioreactor. Biochem Eng J. 2001; 8: 19-29.
39. Betts JI. The Design and Characterisation of Miniature Bioreactors for Microbial Fermentation Process Development, PhD Thesis. University of London; 2006.
40. Tustian AD. An Engineering Study of Key Interactions Within the Process for Antibody Fragment Production, PhD Thesis. University College London; 2008.
41. Moore JD, Perez-Pardo MA, Popplewell JF, Spencer SJ, Ray S, Swann MJ, Shard AG, Jones W, Hills A, Bracewell DG. Chemical and biological characterisation of a sensor surface for bioprocess monitoring. Biosens Bioelectron. 2011; 26: 2940-2947.