Andreas E. Posch

Science-based bioprocess design for filamentous fungi.

Industrial bioprocesses are commonly based on empiricism rather than scientific process understanding. In this review, we summarize current strategies for science-based bioprocess design and control for filamentous fungi aiming at reducing development times and increasing process economics. We discuss recent developments and trends regarding three crucial aspects throughout the bioprocess life cycle of filamentous fungi, namely (i) strain and inoculum characterization, (ii) morphology, and (iii) rheology, as well as their effects on process performance. Complex interconnections between strain, inoculum, morphology, rheology, and process design are outlined and discussed. Only combining different hard type sensors with soft sensor technology and the development of simplified mechanistic models can enable science-based bioprocess design for filamentous fungi.

A novel method for fast and statistically verified morphological characterization of filamentous fungi.

Along with productivity and physiology, morphological growth behavior is the key parameter in bioprocess design for filamentous fungi. Despite complex interactions between fungal morphology, broth viscosity, mixing kinetics, transport characteristics and process productivity, morphology is still commonly tackled only by empirical trial-and-error techniques during strain selection and process development procedures. In fact, morphological growth characteristics are investigated by computational analysis of only a limited number of pre-selected microscopic images or via manual evaluation of images, which causes biased results and does not allow any automation or high-throughput quantification. To overcome the lack of tools for fast, reliable and quantitative morphological analysis, this work introduces a method enabling statistically verified quantification of fungal morphology in accordance with Quality by Design principles. The novel, high-throughput method presented here interlinks fully automated recording of microscopic images with a newly developed evaluation approach reducing the need for manual intervention to a minimum. Validity of results is ensured by concomitantly testing the acquired sample for representativeness by statistical inference via bootstrap analysis. The novel approach for statistical verification can be equally applied as control logic to automatically proceed with morphological analysis of a consecutive sample once user defined acceptance criteria are met. Hence, analysis time can be reduced to an absolute minimum. The quantitative potential of the developed methodology is demonstrated by characterizing the morphological growth behavior of two industrial Penicillium chrysogenum production strains in batch cultivation.

Combining light microscopy, dielectric spectroscopy, MALDI intact cell mass spectrometry, FTIR spectromicroscopy and multivariate data mining for morphological and physiological bioprocess characterization of filamentous organisms

Along with productivity and physiology, morphological growth behavior is the key parameter in bioprocess design for filamentous fungi. Lacking tools for fast, reliable and efficient analysis however, fungal morphology is still commonly tackled by empirical trial-and-error techniques during strain selection and process development procedures. Bridging the gap, this work presents a comprehensive analytical approach for morphological analysis combining automated high-throughput microscopy, multi-frequency dielectric spectroscopy, MALDI intact cell mass spectrometry and FTIR spectromicroscopy. Industrial fed-batch production processes were investigated in fully instrumented, automated bioreactors using the model system Penicillium chrysogenum. Physiological process characterization was based on the determination of specific conversion rates as scale-independent parameters. Conventional light microscopic morphological analysis was based on holistic determination of time series for more than 30 morphological parameters and their frequency distributions over the respective parameter range by automated high-throughput light microscopy. Characteristic protein patterns enriched in specific morphological and physiological states were further obtained by MALDI intact cell mass spectrometry. Spatial resolution of molecular biomass composition was facilitated by FTIR spectromicroscopy. Real-time in situ monitoring of morphological process behavior was achieved by linking multi-frequency dielectric spectroscopy with above outlined off-line methods. Data integration of complementing orthogonal techniques for morphological and physiological analysis together with multivariate modeling of interdependencies between morphology, physiology and process parameters facilitated complete bioprocess characterization. The suggested approach will thus help understanding morphological and physiological behavior and, in turn, allow to control and optimize those complex processes.

Switching industrial production processes from complex to defined media: method development and case study using the example of Penicillium chrysogenum

BackgroundFilamentous fungi are versatile cell factories and widely used for the production of antibiotics, organic acids, enzymes and other industrially relevant compounds at large scale. As a fact, industrial production processes employing filamentous fungi are commonly based on complex raw materials. However, considerable lot-to-lot variability of complex media ingredients not only demands for exhaustive incoming components inspection and quality control, but unavoidably affects process stability and performance. Thus, switching bioprocesses from complex to defined media is highly desirable.ResultsThis study presents a strategy for strain characterization of filamentous fungi on partly complex media using redundant mass balancing techniques. Applying the suggested method, interdependencies between specific biomass and side-product formation rates, production of fructooligosaccharides, specific complex media component uptake rates and fungal strains were revealed. A 2-fold increase of the overall penicillin space time yield and a 3-fold increase in the maximum specific penicillin formation rate were reached in defined media compared to complex media.ConclusionsThe newly developed methodology enabled fast characterization of two different industrial Penicillium chrysogenum candidate strains on complex media based on specific complex media component uptake kinetics and identification of the most promising strain for switching the process from complex to defined conditions. Characterization at different complex/defined media ratios using only a limited number of analytical methods allowed maximizing the overall industrial objectives of increasing both, method throughput and the generation of scientific process understanding.

Multi-analyte quantification in bioprocesses by Fourier-transform-infrared spectroscopy by partial least squares regression and multivariate curve resolution

Graphical abstract

Physiological description of multivariate interdependencies between process parameters, morphology and physiology during fed-batch penicillin production

Optimization of productivity and economics of industrial bioprocesses requires characterization of interdependencies between process parameters and process performance. In the case of penicillin production, as in other processes, process performance is often closely interlinked with the physiology and morphology of the organism used for production. This study presents a systematic approach to efficiently characterize the physiological effects of multivariate interdependencies between bioprocess design parameters (spore inoculum concentration, pO2 control level and substrate feed rate), morphology, and physiology. Method development and application was performed using the industrial model process of penicillin production. Applying traditional, statistical bioprocess analysis, multivariate correlations of raw bioprocess design parameters (high spore inoculum concentration, low pO2 control as well as reduced glucose feeding) and pellet morphology were identified. A major drawback of raw design parameter correlation models; however, is the lack of transferability across different process scales and regimes. In this context, morphological and physiological bioprocess modeling based on scalable physiological parameters is introduced. In this study, raw parameter effects on pellet morphology were efficiently summarized by the physiological parameter of the biomass yield per substrate. Finally, for the first time to our knowledge, the specific growth rate per spore was described as time‐independent determinant for switching from pellet to disperse growth during penicillin production and thus introduced as a novel, scalable key process parameter for pellet morphology and process performance.

Comparison of Fiber Optic and Conduit Attenuated Total Reflection (ATR) Fourier Transform Infrared (FT-IR) Setup for In-Line Fermentation Monitoring.

The performance of a fiber optic and an optical conduit in-line attenuated total reflection mid-infrared (IR) probe during in situ monitoring of Penicillium chrysogenum fermentation were compared. The fiber optic probe was connected to a sealed, portable, Fourier transform infrared (FT-IR) process spectrometer via a plug-and-play interface. The optical conduit, on the other hand, was connected to a FT-IR process spectrometer via a knuckled probe with mirrors that had to be adjusted prior to each fermentation, which were purged with dry air. Penicillin V (PenV) and its precursor phenoxyacetic acid (POX) concentrations were determined by online high-performance liquid chromatography and the obtained concentrations were used as reference to build partial least squares regression models. Cross-validated root-mean-square errors of prediction were found to be 0.2 g L−1 (POX) and 0.19 g L−1 (PenV) for the fiber optic setup and 0.17 g L−1 (both POX and PenV) for the conduit setup. Higher noise-levels and spectrum-to-spectrum variations of the fiber optic setup lead to higher noise of estimated (i.e., unknown) POX and PenV concentrations than was found for the conduit setup. It seems that trade-off has to be made between ease of handling (fiber optic setup) and measurement accuracy (optical conduit setup) when choosing one of these systems for bioprocess monitoring.

Imaging Flow Cytometry and High-Throughput Microscopy for Automated Macroscopic Morphological Analysis of Filamentous Fungi

Traditional methods for automated and high-throughput morphological analysis of filamentous fungi can be time-consuming and difficult. Here, two suitable image acquisition methods and subsequent image and data processing steps are presented. The acquisition methods are based on imaging flow cytometry and whole-slide microscopy. Guidelines for developing customized image and data analysis routines for satisfying individual research requirements are presented.

Intact cell mass spectrometry as a progress tracking tool for batch and fed-batch fermentation processes.

Penicillin production during a fermentation process using industrial strains of Penicillium chrysogenum is a research topic permanently discussed since the accidental discovery of the antibiotic. Intact cell mass spectrometry (ICMS) can be a fast and novel monitoring tool for the fermentation progress during penicillin V production in a nearly real-time fashion. This method is already used for the characterization of microorganisms and the differentiation of fungal strains; therefore, the application of ICMS to samples directly harvested from a fermenter is a promising possibility to get fast information about the progress of fungal growth. After the optimization of the ICMS method to penicillin V fermentation broth samples, the obtained ICMS data were evaluated by hierarchical cluster analysis or an in-house software solution written especially for ICMS data comparison. Growth stages of a batch and fed-batch fermentation of Penicillium chrysogenum are differentiated by one of those statistical approaches. The application of two matrix-assisted laser desorption/ionization time-of-flight (MALDI-TOF) instruments in the linear positive ion mode from different vendors demonstrated the universal applicability of the developed ICMS method. The base for a fast and easy-to-use method for monitoring the fermentation progress of P. chrysogenum is created with this ICMS method developed especially for fermentation broth samples.

Evaluating online sampling probes for substrate concentration and protein production by a Design of Experiments screening approach

A polypropylene sampling probe and ceramic sampling probe were tested for the online measurement of substrate and protein concentrations in fed batch cultivations of a recombinant Pichia pastoris strain overexpressing the enzyme HRP. Although small substrate molecules could be determined precisely under process conditions, online and offline data for enzyme activity and protein content showed offsets for both sampling probes. An easy‐to‐do multivariate Design of Experiments (DoE) screening approach revealed the limitations for both sampling probes. Online and offline determined data for enzymatic activity were fitted to a suitable exponential equation. A direct correlation of these equations showed a linear relation between online and offline data for the polypropylene probe and a quadratic relation for the ceramic probe. Using the resulting formulas, observed offsets could be compensated for by mathematical transformation, which consequently could allow the use of online calculator tools to determine the enzymatic activity and the protein content in quasi real‐time. This study demonstrates the usefulness of a DoE approach to evaluate online sampling probes in a short time and introduces a strategy to obtain data with two different online sampling probes also for large target molecules despite observed offsets.