Model Predictive Feeding Rate Control in Conventional and Single-use Lab-scale Bioreactors: A Study on Practical Application

A developed solution for fed-batch process modeling and model predictive control (MPC), facilitating good manufacturing practice (GMP) based on process elaboration, control, and validation, is presented in the paper. The step-by-step evolution of the so-called “golden batch” optimal biomass growth profile and its control during the process is demonstrated. The case study of an advanced fed-batch control was performed on the recombinant E. coli BL21 lab-scale (5.4 L) biomass production process using the conventional stirred tank glass reactor. Additionally, a test experiment for control reproducibility and applicability assessment of the proposed approach was carried out in a single-use stirred tank reactor (5.7 L). Four sequentially performed experiments are demonstrated as an example for desirable feeding profile evolution for E. coli BL21 biomass production in a glucose-limited fed-batch process. Under different initial biomass and glucose conditions, as well as for different reference feeding profiles selected in the explorative experiments, good tracking quality of preset reference trajectories by the MPC system has been demonstrated. Estimated and experimentally measured biomass mean deviations from the preset reference value at the end of the processes were 4.6 and 3.8 %, respectively. Biomass concentration of 93.6 g L–1 (at 24 h) was reached in the most productive run. Better process controllability and safer process run, in terms of avoiding culture overfeeding but still maintaining a sufficiently high growth rate, was suggested for the process with biomass yield of 79.8 g L–1 (at 24 h). Practical recommendations on the approach application and adaptation for fed-batch cultures of interest are provided

Application of In-Situ and Soft-Sensors for Estimation of Recombinant P. pastoris GS115 Biomass Concentration: A Case Analysis of HBcAg (Mut+) and HBsAg (MutS) Production Processes under Varying Conditions

Microbial biomass concentration is a key bioprocess parameter, estimated using various labor, operator and process cross-sensitive techniques, analyzed in a broad context and therefore the subject of correct interpretation. In this paper, the authors present the results of P. pastoris cell density estimation based on off-line (optical density, wet/dry cell weight concentration), in-situ (turbidity, permittivity), and soft-sensor (off-gas O2/CO2, alkali consumption) techniques. Cultivations were performed in a 5 L oxygen-enriched stirred tank bioreactor. The experimental plan determined varying aeration rates/levels, glycerol or methanol substrates, residual methanol levels, and temperature. In total, results from 13 up to 150 g (dry cell weight)/L cultivation runs were analyzed. Linear and exponential correlation models were identified for the turbidity sensor signal and dry cell weight concentration (DCW). Evaluated linear correlation between permittivity and DCW in the glycerol consumption phase (<60 g/L) and medium (for Mut+ strain) to significant (for MutS strain) linearity decline for methanol consumption phase. DCW and permittivity-based biomass estimates used for soft-sensor parameters identification. Dataset consisting from 4 Mut+ strain cultivation experiments used for estimation quality (expressed in NRMSE) comparison for turbidity-based (8%), permittivity-based (11%), O2 uptake-based (10%), CO2 production-based (13%), and alkali consumption-based (8%) biomass estimates. Additionally, the authors present a novel solution (algorithm) for uncommon in-situ turbidity and permittivity sensor signal shift (caused by the intensive stirrer rate change and antifoam agent addition) on-line identification and minimization. The sensor signal filtering method leads to about 5-fold and 2-fold minimized biomass estimate drifts for turbidity- and permittivity-based biomass estimates, respectively

Investigation of a Broad-Bean Based Low-Cost Medium Formulation for <i>Bacillus subtilis</i> MSCL 897 Spore Production

Bacillus subtilis (Bs) is a bacterium that benefits plants and is used in the production of bio-fungicides. The cultivation of Bs is a crucial step in bio-control preparation production, as it greatly impacts the quality and price of the final product. In a series of shake flask experiments, we investigated the economically feasible broth composition for spore production of Bacillus subtilis MSCL 897, a Latvian soil isolate. Our study investigated the impact of utilizing legume-based flours (such as broad bean, grey pea, and soybean) as the primary nitrogen source, along with sugar-beet molasses, sucrose, or glucose as the carbon source, and yeast extract, peptone, and corn-steep liquor as growth factor additives. Additionally, we examined the effect of using (NH4)2HPO4 or urea as supplementary nitrogen sources, as well as previously established media formulations, on spore yield. Our results showed that a culture medium composed of broad bean flour (10 g/L) and molasses (10 g/L) led to spore productivity of 1.35 ± 0.47 × 108 CFU/mL at 48 h. By enriching the culture medium base constituents with a minor (0.5–1.0 g/L) yeast extract or corn-steep liquor additive, a notable increase in spore productivity was observed, with values of 2.00 ± 0.28 × 108 and 2.34 ± 0.18 × 108 CFU/mL at 48 h, respectively, and sporulation efficiency > 80–90%. As a result, we achieved a high spore yield of the Bacillus subtilis MSCL 897 strain, demonstrating the competitiveness of our approach, which relied on a low-cost medium made mainly from locally available and renewable raw materials

The Effect of Dopants on Sintering and Microstructure of Lead-free KNN Ceramics

Lead-free potassium sodium niobate (K0.5Na0.5)NbO3 (KNN) has been prepared via conventional ceramic processing method. The influence of 0.5 wt% - 1.5 wt% MnO2 and WO3 addition on the sintering, crystallographic structure, microstructure and dielectric properties of KNN has been investigated. Optimal sintering temperatures of KNN ceramics were observed to be in the narrow interval: 1090 °C - 1110 °C for MnO2 doped KNN; 1150 °C - 1170 °C for pure KNN and doped with WO3. XRD patterns showed that all the samples have single perovskite structure with monoclinic structure. Microstructure of ceramics was changed greatly by using dopants.http://dx.doi.org/10.5755/j01.ms.17.1.251</p

Application of a Posttreatment to Improve the Viability and Antifungal Activity of Trichoderma asperellum Biomass Obtained in a Bioreactor during Submerged Cultivation

T. asperellum MSCL 309 was used in the study. T. asperellum was grown in the stirred bioreactor under submerged cultivation. The resulting biomass was filtered to obtain a thick biomass. The viability and antifungal activity of T. asperellum biomass samples were determined simultaneously by studying the colonization of the malt extract agar medium surface and its competitiveness with the plant pathogenic fungus Fusarium graminearum using in vitro dual culture experiments. Treatment with starch, alone or in combination with copper (II) sulphate and/or hydrochloric acid did not significantly affect fungal viability compared to control. An important factor in maintaining viability was the addition of hydrochloric acid, which significantly increased the storage life of biomass. In all post-treatments, F. graminearum was overgrown with T. asperellum in seven days, and accordingly, the larger the area occupied by T. asperellum, the smaller the area of F. graminearum colonization. Viability and antifungal activity of T. asperellum persisted throughout the experiment, at least for eight weeks. All the post-treatment methods we studied improved the viability and antifungal activity of Trichoderma, at least in terms of the area of the colonized surface. For the development of long-term viable and active T. asperellum preparations, we recommend the use of acidification of T. asperellum biomass obtained by submerged fermentation

Principles and application of pO2 cascade control in fermentation processes

Many of industrially used fermentation processes require reliable and precise control of system’s aeration level by means of pO2 (dissolved oxygen partial pressure) control. Most of currently available fermentation systems use pO2 control in so-called cascade control way, e.g., control of pO2 by aeration flow, stirrer speed, oxygen enrichment, and feeding rate under substrate limitation conditions. Following research contain experimental result where pO2 cascade control principle was applied to Escherichia coli and Saccharomyces cerevisiae fermentation processes

Optimization of Synthetic Media Composition for Kluyveromyces marxianus Fed-Batch Cultivation

The Kluyveromyces marxianus yeast recently has gained considerable attention due to its applicability in high-value-added product manufacturing. In order to intensify the biosynthesis rate of a target product, reaching high biomass concentrations in the reaction medium is mandatory. Fed-batch processes are an attractive and efficient way how to achieve high cell densities. However, depending on the physiology of the particular microbial strain, an optimal media composition should be used to avoid by-product synthesis and, subsequently, a decrease in overall process effi-ciency. Thus, the aim of the present study was to optimise the synthetic growth medium and feeding solution compositions (in terms of carbon, nitrogen, phosphorous, magnesium, and calcium concentrations) for high cell density K. marxianus fed‑batch cultivations. Additionally, the biomass yields from the vitamin mixture and other macro/microelements were identified. A model predictive control algorithm was successfully applied for a fed-batch cultivation control. Biomass growth and substrate consumption kinetics were compared with the mathematical model predictions. Finally, 2‑phenylethanol biosynthesis was induced and its productivity was estimated. The determined optimal macronutrient ratio for K. marxianus biomass growth was identified as C:N:P = 1:0.07:0.011. The maximal attained yeast biomass concentration was close to 70 g·L-1 and the 2-PE biosynthesis rate was 0.372 g·L−1·h−1, with a yield of 74% from 2-phenylalanine