During the past decade much progress has been made in the fundamental understanding of the phenomena that govern biocatalysis in non-conventional media. The factors that affect biocatalytic reactions and the activity and stability of biocatalysts in these reaction media are generally associated with the crucial role of water and the need to keep biocatalysts in their active conformation. For the rational design of biocatalytic processes in the reaction media, discussed in this review, some basic rules have been formulated. These rules may serve as useful tools for future optimization of biocatalysis in nonconventional media and for engineering media for synthetic purposes.

Thirty five years ago the first European Congress on Biotechnology took place in Interlaken, Switzerland. At this meeting the European Foundation of Biotechnology (EFB) was founded. The pillars of ...

In ethanol production from cellulose, enzymatic hydrolysis, and fermentative conversion may be performed sequentially (separate hydrolysis and fermentation, SHF) or in a single reaction vessel (simultaneous saccharification and fermentation, SSF). Opting for either is essentially a trade-off between optimal temperatures and inhibitory glucose concentrations on the one hand (SHF) vs. sub-optimal temperatures and ethanol-inhibited cellulolysis on the other (SSF). Although the impact of ethanol on cellobiose hydrolysis was found to be negligible, formation of glucose and cellobiose from cellulose were found to be significantly inhibited by ethanol. A previous model for the kinetics of enzymatic cellulose hydrolysis was, therefore, extended with enzyme inhibition by ethanol, thus allowing a rational evaluation of SSF and SHF. The model predicted SSF processing to be superior. The superiority of SSF over SHF (separate hydrolysis and fermentation) was confirmed experimentally, both with respect to ethanol yield on glucose (0.41 g g(-1) for SSF vs. 0.35 g g(-1) for SHF) and ethanol production rate, being 30% higher for an SSF type process. High conversion rates were found to be difficult to achieve since at a conversion rate of 52% in a SSF process the reaction rate dropped to 5% of its initial value. The model, extended with the impact of ethanol on the cellulase complex proved to predict reaction progress accurately.

In the enzymatic production of antibiotics, membranes can be used for different purposes. Since the enzyme is a cost-determining factor, membrane bioreactors in which the ultrafiltration membrane’s sole purpose is retention of the ‘free’ enzyme and recycling it to the reaction vessel, were investigated as an alternative for the current immobilised-enzyme based process. The membrane bioreactor was tested for two reactions, the production of one of the substrates for the antibiotic synthesis, and the actual enzymatic synthesis reaction. The first process could be improved considerably if the pH regulation took place right after the membrane, therewith creating a small loop that prevented direct contact of the enzyme with high pH, for which it is very sensitive. For the latter process, a big advantage was that diffusion limitation, which reduces the yield of the process with immobilised enzyme, does not take place. Besides, options for continuous operation became available. Away from application during the enzymatic reactions, (nanofiltration) membranes were useful for down-stream processing of one of the substrates for antibiotic synthesis. Some of the tested membranes showed separation behaviour, which was strongly pH dependent, therewith opening new options for isolation of the desired component.

A licensed pharmaceutical process is required to be executed within the validated ranges throughout the lifetime of product manufacturing. Changes to the process, especially for processes involving biological products, usually require the manufacturer to demonstrate that the safety and efficacy of the product remains unchanged by new or additional clinical testing. Recent changes in the regulations for pharmaceutical processing allow broader ranges of process settings to be submitted for regulatory approval, the so‐called process design space, which means that a manufacturer can optimize his process within the submitted ranges after the product has entered the market, which allows flexible processes. In this article, the applicability of this concept of the process design space is investigated for the cultivation process step for a vaccine against whooping cough disease. An experimental design (DoE) is applied to investigate the ranges of critical process parameters that still result in a product that meets specifications. The on‐line process data, including near infrared spectroscopy, are used to build a descriptive model of the processes used in the experimental design. Finally, the data of all processes are integrated in a multivariate batch monitoring model that represents the investigated process design space. This article demonstrates how the general principles of PAT and process design space can be applied for an undefined biological product such as a whole cell vaccine. The approach chosen for model development described here, allows on line monitoring and control of cultivation batches in order to assure in real time that a process is running within the process design space. Biotechnol. Bioeng. 2009; 104: 492–504 © 2009 Wiley Periodicals, Inc.

Multiple phenomena are involved in conversions by immobilized biocatalysts. A paradox is identified between analytical desires on one hand and analytical boundary conditions on the other: while the study of interdependent phenomena would call for their simultaneous analysis in an integrated context, the available experimental options may impose a series of separate and dedicated analyses. From this analysis, bottlenecks in particle performance may be identified, if possible supported by a mechanistic model and performance criteria. Subsequently, a strategy for further biocatalyst development may be chosen. Finally, possibilities for future improvement of biocatalysts are discussed for various fields of research. Some examples of recent developments in enzyme and matrix characteristics, reactor operation, and micro-technology are discussed.

The kinetics of cellulose hydrolysis by commercially available Cellubrix were described mathematically, with Avicel and wheat straw as substrates. It was demonstrated that hydrolysis could be described by three reactions: direct glucose formation and indirect glucose formation via cellobiose. Hydrolysis did not involve any soluble oligomers apart from low amounts of cellobiose. Phenomena included in the mathematical model were substrate limitation, adsorption of enzyme onto substrate, glucose inhibition, temperature dependency of reaction rates, and thermal enzyme inactivation. In addition, substrate heterogeneity was described by a recalcitrance constant. Model parameters refer to both enzyme characteristics and substrate-specific characteristics.Quantitative model development was carried out on the basis of Avicel hydrolysis. In order to describe wheat straw hydrolysis, wheat straw specific parameter values were measured. Updating the pertinent parameters for wheat straw yielded a satisfactory description of wheat straw hydrolysis, thus underlining the generic potential of the model.

The combination of web technology, knowledge of bioprocess engineering, and theories on learning and instruction might yield innovative learning material for bioprocess engineering. In this article, an overview of the characteristics of web-based learning material is given, as well as guidelines for the design of learning material from theories of learning and instruction and from the bioprocess engineering domain. A diverse body of learning material is presented, which illustrates the application of these guidelines; this material has been developed during the past six years for different courses, mostly at undergraduate level, and it illustrates how web-based learning material can enable various different approaches to learning objectives that might improve overall learning. Such learning material has been used for several years in education, it has been evaluated with positive results, and is now part of the regular learning material for bioprocess engineering at Wageningen University.

There is a need for novel protein sources. Insects are a possible interesting source of protein. They are nutritious in terms of protein (40-75 g/100g dry weight) and minerals. Insect protein is of high quality and has a high digestibility (77-98%) and concentration of essential amino acids (46-96% of the nutritional profile). Also insect cells may be a promising novel source of protein. Choice of cell line, growth conditions and use of the baculovirus expression system opens up possibilities to engineer the nutritional value of the biomass. The technological limits as well as consumer acceptance of insect cell based food remains to be investigated.

A physical model was derived for the synthesis of the antibiotic cephalexin with an industrial immobilized penicillin G acylase, called Assemblase. In reactions catalyzed by Assemblase, less product and more by-product are formed in comparison with a free-enzyme catalyzed reaction. The model incorporates reaction with a heterogeneous enzyme distribution, electrostatically coupled transport, and pH-dependent dissociation behavior of reactants and is used to obtain insight in the complex interplay between these individual processes leading to the suboptimal conversion. The model was successfully validated with synthesis experiments for conditions ranging from heavily diffusion limited to hardly diffusion limited, including substrate concentrations from 50 to 600 mM, temperatures between 273 and 303 K, and pH values between 6 and 9. During the conversion of the substrates into cephalexin, severe pH gradients inside the biocatalytic particle, which were previously measured by others, were predicted. Physical insight in such intraparticle process dynamics may give important clues for future biocatalyst design. The modular construction of the model may also facilitate its use for other bioconversions with other biocatalysts.

Marine sponges are known to produce an overwhelming array of secondary metabolites with pharmaceutical potential. The technical and economical potential of using marine sponges for large-scale production of these compounds was assessed for two cases: the anticancer molecule halichondrin B from a Lissodendoryx sp., and avarol from Dysidea avara for its antipsoriasis activity. An economic and technical analysis was done for three potential production methods: mariculture, ex situ culture (in tanks), and cell culture. We concluded that avarol produced by mariculture or ex situ culture could become a viable alternative to currently used pharmaceuticals for the treatment of psoriasis. Production of halichondrin B from sponge biomass was found to not be a feasible process, mainly due to the extremely low concentration of the compound in the sponge. Technical feasibility was also analyzed for five alternatives: chemical synthesis, wild harvest, primmorph culture, genetic modification and semi-synthesis. It was concluded that the latter two approaches could prove to be valuable methods for the production of pharmaceuticals, based on chemical structures of secondary metabolites present in trace amounts in marine sponges. (c) 2005 Wiley Periodicals, Inc.

A highly interconnecting and accessible pore network has been suggested as one of a number of prerequisites in the design of scaffolds for tissue engineering. In the present study, two processing techniques, compression-molding/particulate-leaching (CM), and 3D fiber deposition (3DF), were used to develop porous scaffolds from biodegradable poly(ethylene glycol)-terephthalate/poly(butylene terephthalate) (PEGT/PBT) co-polymers with varying pore architectures. Three-dimensional micro-computed tomography (μCT) was used to characterize scaffold architectures and scaffolds were seeded with articular chondrocytes to evaluate tissue formation. Scaffold porosity ranged between 75% and 80%. Average pore size of tortuous CM scaffolds (182 μm) was lower than those of organized 3DF scaffolds (525 μm). The weight ratio of glycosaminoglycans (GAG)/DNA, as a measure of cartilage-like tissue formation, did not change after 14 days of culture whereas, following subcutaneous implantation, GAG/DNA increased significantly and was significantly higher in 3DF constructs than in CM constructs, whilst collagen type II was present within both constructs. In conclusion, 3DF PEGT/PBT scaffolds create an environment in vivo that enhances cartilaginous matrix deposition and hold particular promise for treatment of articular cartilage defects.

In a study of Assemblase®, an industrial immobilized penicillin-G acylase, various electron microscopic techniques were used to relate intra-particle enzyme heterogeneity with the morphological heterogeneity of the support material at various levels of detail. Transmission electron microscopy was used for the study of intra-particle penicillin-G acylase distribution in Assemblase® particles of various sizes; it revealed an abrupt increase in enzyme loading at the particle surface (1.4-fold) and in the areas (designated halo's) surrounding internal macro-voids (7.7-fold). Cryogenic field-emission scanning electron microscopy related these abrupt local enzyme heterogeneities to local heterogeneity of the support material by revealing the presence of dense top layers surrounding both the particle exterior and the internal macro-voids. Furthermore, it showed a very distinct morphological appearance of the halo. Most probably, all these regions contained relatively more chitosan than gelatin (the polymers Assemblase® was constructed of), which suggested local polymer demixing during particle production. A basic thermodynamic line of reasoning suggested that a difference in hydrophilicity between the two polymers induced local demixing. In the future, thermodynamic knowledge on such polymer interactions resulting in matrix heterogeneity may be used as a tool for biocatalyst design.

The quantitative intraparticle enzyme distribution of Assemblase, an industrially employed polydisperse immobilized penicillin-G acylase, was measured. Because of strong autofluorescence of the carrier, the generally applied technique of confocal scanning microscopy could not be used; light microscopy was our method of choice. To do so, Assemblase particles of various sizes were sectioned, labeled with antibodies specifically against the enzyme, and analyzed light microscopically. Image analysis software was developed and used to determine the intraparticle enzyme distribution, which was found to be heterogeneous, with most enzyme located in the outer regions of the particles. Larger particles showed steeper gradients than smaller ones. A mathematical representation of the intraparticle profiles, based on in-stationary enzyme diffusion into the particles, was validated successfully for a broad range of particle sizes using data for volume-averaged particle size and enzyme loading. The enzyme gradients determined in this work will be used as input for a physical model that quantitatively describes the complex behavior of Assemblase. Such a physical model will lead to identification of the current bottlenecks in Assemblase and can serve as a starting point for the design of improved biocatalysts that also may be based on intelligent use of enzyme gradients.

Field-emission scanning electron microscopy (FESEM) was used in a technical feasibility study to obtain insight into the internal morphology and the intraparticle enzyme distribution of Assemblase, an industrial biocatalytic particle containing immobilized penicillin-G acylase. The results were compared with previous studies based on light and transmission electron microscopic techniques. The integrated FESEM approach yielded the same quantitative results as the microscopic techniques used previously. Given this technical equivalence, the integrated approach offers several advantages. First, the single preparation method and detection system avoids interpretation discrepancies between corresponding areas that were examined for different properties with different detection techniques in different samples. Second, the specimen size suitable for whole particle study is virtually unlimited, which simplifies sectioning and puts less stringent demands on the embedding technique. Furthermore, the sensitivity toward enzyme presence and distribution increases because the epitopes inside thick sections become available for labeling. Quick and unambiguous analysis of the relation between particle morphology and enzyme distribution is important because this information may be used in the future for the design of enzyme distributions in which the particle morphology can be used as a control parameter.

In this paper, the effects of bed porosity, bran and specific surface area on the oxygen uptake rate and α-amylase production during growth of Aspergillus oryzae on wheat grain and wheat–flour substrate are reported. The high oxygen uptake rate found during cultivation of A. oryzae on wheat–flour substrate was not reached on wheat grain. This is mainly due to the bran of the wheat grain. Using wheat–flour substrates, it was shown that extra bed porosity increased the α-amylase production and oxygen uptake rates. Furthermore, the peak oxygen uptake rate decreased with increasing surface area–volume ratio of the substrate particles, while the α-amylase production and the cumulative oxygen uptake per gram of initial substrate dry matter increased. The present work does not support a direct correlation between aerial mycelia and enzyme production. There is, however, a correlation between the α-amylase yield and the cumulative oxygen uptake (not the uptake rate). This implies that aerial mycelia could accelerate α-amylase production even if they do not increase the yield.

A liquid-fluidized bed or packed bed with gel beads is attractive as an immobilized-cell bioreactor. The performance of such bioreactors is influenced by the physical behavior of these beads. Three different but related aspects involving the drag force between particles and liquid were studied for five types of gel beads, differing in diameter and density: (1) the terminal settling velocity of a single gel bead, (2) the pressure drop over a packed bed and (3) the voidage in a liquid-fluidized bed. Qualitatively, the same trends in these aspects were observed for gel beads as for conventional solids. Quantitatively, however, these aspects were incorrectly predicted by established models (with one exception).It was found that the drag force between gel bead and flowing liquid is smaller than that for conventional solids. As an explanation, two hypotheses are suggested. The first one attributes the drag reduction to small amounts of dissolved polymer. The second one attributes the smaller drag force to the surface nature of gel beads: gel beads contain over 95% of water and thus can be regarded as 'rigid' water droplets. Hence, the gel bead surface might show water-like properties.As an alternative to drag-coefficient relations for conventional solids, the drag coefficient of a single gel bead in a packed or fluidized bed could successfully be described by adapting an existing relation. The success of this description facilitates a more rational design of packed and fluidized beds of gel beads. (c) 2005 Elsevier B.V. All rights reserved.

Oxygen transfer in the fungal mat is a major concern in solid-state fermentation (SSF). Oxygen supply into the mycelial layers is hampered by diffusion limitation. For aerobic fungi, like Aspergillus oryzae, this oxygen depletion can be a severely limiting factor for growth and metabolite production. This paper describes the effects of a low oxygen concentration on growth at the levels of individual hyphae, colonies and overcultures, and on α-amylase production in overcultures. PDA medium was used to study the effect of a low oxygen concentration on hyphal elongation rate and branching frequency of hyphae, and radial extension rate of colonies of A. oryzae. We found similar saturation constants (KO2) of 0.1% (v/v in the gas phase) for oxygen concentration described with Monod kinetics, for branching frequency of hyphae and colony extension rate. When A. oryzae was grown as an over-culture on wheat-flour model substrate at 0.25% (v/v) oxygen concentration, the reduction in growth was more pronounced than as individual hyphae and a colony on PDA medium. Experimental results also showed that the specific α-amylase production rate under the condition of 0.25% (v/v) oxygen was reduced. Because the value of KO2 is relatively low, it is reasonable to simplify the kinetics of growth of A. oryzae to zero-order kinetics in coupled diffusion/reaction models.

Immobilized cells of Actinoplanes teichomyceticus ATCC 31121 were used to selectively cleave the acyl group of A40926 yielding the deacylated form of the molecule. The feasibility of this particular biotransformation in a series of three perfectly mixed airlift bioreactors with immobilized cells was examined. A continuously operated airlift cascade was designed using a model for a series of reactors with immobilized biocatalyst beads obeying Michaelis–Menten kinetics. In independent experimental runs the cascade bioreactor system was operated continuously for 56 days with an overall conversion of 99%. Model estimates for reactor volumes and relative conversions were found to be in a good agreement with the experimental results.