Juliane Steingroewer

Bioprocessing of differentiated plant in vitro systems

Plant cells contain a wide range of interesting secondary metabolites, which are used as natural pigments and flavoring agents in foods and cosmetics as well as phyto‐pharmaceutical products. However, conventional industrial extraction from whole plants or parts of them is limited due to environmental and geographical issues. The production of secondary metabolites from in vitro cultures can be considered as alternative to classical technologies and allows a year‐round cultivation in the bioreactor under optimal conditions with constant high‐level quality and quantity. Compared to plant cell suspensions, differentiated plant in vitro systems offer the advantage that they are genetically stable. Moreover, the separation of the biomass from culture medium after fermentation is much easier. Nevertheless, several investigations in the literature described that differentiated plant in vitro systems are instable concerning the yield of the target metabolites, especially in submerged cultivations. Other major problems are associated with the challenges of cultivation conditions and bioreactor design as well as upscaling of the process. This article reviews bioreactor designs for cultivation of differentiated plant in vitro systems, secondary metabolite production in different bioreactor systems as well as aspects of process control, management, and modeling and gives perspectives for future cultivation methods.

Sage in vitro cultures: a promising tool for the production of bioactive terpenes and phenolic substances

Extracts of Salvia species are used in traditional medicine to treat various diseases. The economic importance of this genus has increased in recent years due to evidence that some of its secondary metabolites have valuable pharmaceutical and nutraceutical properties.The bioactivity of sage extracts is mainly due to their content of terpenes and polyphenols. The increasing demand for sage products combined with environmental, ecological and climatic limitations on the production of sage metabolites from field-grown plants have led to extensive investigations into biotechnological approaches for the production of Salvia phytochemicals. The purpose of this review is to evaluate recent progress in investigations of sage in vitro systems as tools for producing important terpenoids and polyphenols and in development of methods for manipulating regulatory processes to enhance secondary metabolite production in such systems.

Growth kinetics of a Helianthus annuus and a Salvia fruticosa suspension cell line: Shake flask cultivations with online monitoring system

Plants produce a variety of secondary metabolites to defend themselves against herbivores or to attract pollinating insects. Plant cell biotechnology offers excellent opportunities in order to use such secondary plant metabolites to produce goods with consistent quality and quantity throughout the year, and therefore to act independently from biotic and abiotic environmental factors. This article presents results of an extensive study of plant cell in vitro cultivation in a modern shake flask system with noninvasive online respiration activity monitoring unit. Comprehensive screening experiments confirm the successful transfer of a model culture (sunflower suspension) into the shake flask monitoring device and the suitability of this respiration activity monitoring unit as qualified tool for screening of plant in vitro cultures (sunflower and sage suspension). The authors demonstrate deviations between online and offline data due to varying water evaporation from different culture flask types. The influence of evaporation on growth‐specific parameters thereby rises with increasing cultivation time. Furthermore, possibilities to minimize the impact of evaporation, either by adjusting the inlet air moisture or by measuring the evaporation in combination with an appropriate correction of the measured growth values are shown.

Automatic image recognition to determine morphological development and secondary metabolite accumulation in hairy root networks

This study focuses on the morphological development and secondary metabolite production of the red pigments from the group of betacyanins in hairy roots of Beta vulgaris. We demonstrate a working, medium throughput, customized, automatic image recognition solution for hairy roots on agar plates including the evaluation of 12 experimental samples. Image acquisition is conducted under comparable para‐meters using a tripod with light emitting diode background lighting and a digital single lens reflex camera. The server‐based image recognition system developed together with Wimasis GmbH, Munich, Germany helps to obtain not only quantitative values for morphological parameters, such as segment lengths and widths or metabolite concentrations, but also global parameters of root growth, such as total root length or the number of branching points. Using timed diagrams the development of the total root length, the total number of branching points, and the mean pigment concentration during the cultivation period were determined. The generated data present the basis for detailed mathematical modeling in order to achieve a structured growth model for hairy roots. A mathematical model for growth of hairy roots can be used to decrease experimental efforts as well as to optimize cultivation conditions and the bioreactor design.

Green bioprinting: extrusion-based fabrication of plant cell-laden biopolymer hydrogel scaffolds

Plant cell cultures produce active agents for pharmaceuticals, food and cosmetics. However, up to now process control for plant cell suspension cultures is challenging. A positive impact of cell immobilization, such as encapsulation in hydrogel beads, on secondary metabolites production has been reported for several plant species. The aim of this work was to develop a method for bioprinting of plant cells in order to allow fabrication of free-formed three-dimensional matrices with defined internal pore architecture for in depth characterization of immobilization conditions, cell agglomeration and interactions. By using extrusion-based 3D plotting of a basil cell-laden hydrogel blend consisting of alginate, agarose and methylcellulose (alg/aga/mc), we could demonstrate that bioprinting is applicable to plant cells. The majority of the cells survived plotting and crosslinking and the embedded cells showed high viability and metabolic activity during the investigated cultivation period of 20 d. Beside its compatibility with the plant cells, the novel alg/aga/mc blend allowed fabrication of defined 3D constructs with open macropores both in vertical and horizontal direction which were stable under culture conditions for several weeks. Thus, Green Bioprinting, an additive manufacturing technology processing live cells from the plant kingdom, is a promising new immobilization tool for plant cells that enables the development of new bioprocesses for secondary metabolites production as well as monitoring methods.

Mass propagation of Helianthus annuus suspension cells in orbitally shaken bioreactors: Improved growth rate in single‐use bag bioreactors

Stirred tank‐bioreactors made of glass or steel, wave‐mixed, and orbitally shaken bag bioreactors have all proven to be suitable for the rapid development and commercial production of bioactive compounds with plant cell suspensions. Although these bag bioreactors are characterized by reduced foam formation and less flotation in comparison to stirred systems, their power input is limited. Engineering parameters such as mixing time, oxygen transfer, and power input are dependent on the viscosity of the liquid and thus, investigations with plant cell suspensions are necessary. However, to save time and achieve better controllability, sodium carboxymethyl cellulose (Na‐CMC) solutions in concentrations ranging from 1 to 20 g L−1, with viscosities of between 0.005 and 0.4 Pa·s, were identified as appropriate model systems for mimicking plant cell suspensions with packed cell volumes of between 30 and 70 % and similar viscosities. The current study has shown that it is possible to transfer a Helianthus annuus cell suspension process from an orbitally shaken CultiBag RM 1 L to a CultiBag RM with a 10 L working volume by adjusting the operating parameters to achieve a constant kLa value. A maximum specific growth rate μmax of around 0.25 d−1 was achieved, which corresponds to optimized data for shake flasks and even exceeds the growth rate for stirred glass bioreactors.

Modeling hairy root tissue growth in in vitro environments using an agent-based, structured growth model

An agent-based model for simulating the in vitro growth of Beta vulgaris hairy root cultures is described. The model fitting is based on experimental results and can be used as a virtual experimentator for root networks. It is implemented in the JAVA language and is designed to be easily modified to describe the growth of diverse biological root networks. The basic principles of the model are outlined, with descriptions of all of the relevant algorithms using the ODD protocol, and a case study is presented in which it is used to simulate the development of hairy root cultures of beetroot (Beta vulgaris) in a Petri dish. The model can predict various properties of the developing network, including the total root length, branching point distribution, segment distribution and secondary metabolite accumulation. It thus provides valuable information that can be used when optimizing cultivation parameters (e.g., medium composition) and the cultivation environment (e.g., the cultivation temperature) as well as how constructional parameters change the morphology of the root network. An image recognition solution was used to acquire experimental data that were used when fitting the model and to evaluate the agreement between the simulated results and practical experiments. Overall, the case study simulation closely reproduced experimental results for the cultures grown under equivalent conditions to those assumed in the simulation. A 3D-visualization solution was created to display the simulated results relating to the state of the root network and its environment (e.g., oxygen and nutrient levels).

Additive Biotech—Chances, challenges, and recent applications of additive manufacturing technologies in biotechnology

The diversity and complexity of biotechnological applications are constantly increasing, with ever expanding ranges of production hosts, cultivation conditions and measurement tasks. Consequently, many analytical and cultivation systems for biotechnology and bioprocess engineering, such as microfluidic devices or bioreactors, are tailor-made to precisely satisfy the requirements of specific measurements or cultivation tasks. Additive manufacturing (AM) technologies offer the possibility of fabricating tailor-made 3D laboratory equipment directly from CAD designs with previously inaccessible levels of freedom in terms of structural complexity. This review discusses the historical background of these technologies, their most promising current implementations and the associated workflows, fabrication processes and material specifications, together with some of the major challenges associated with using AM in biotechnology/bioprocess engineering. To illustrate the great potential of AM, selected examples in microfluidic devices, 3D-bioprinting/biofabrication and bioprocess engineering are highlighted.

Phototrophic growth of Arthrospira platensis in a respiration activity monitoring system for shake flasks (RAMOS

Optimizing illumination is essential for optimizing the growth of phototrophic cells and their production of desired metabolites and/or biomass. This requires appropriate modulation of light and other key inputs and continuous online monitoring of their metabolic activities. Powerful noninvasive systems for cultivating heterotrophic organisms include shake flasks in online monitoring units, but they are rarely used for phototrophs because they lack the appropriate illumination design and necessary illuminatory power. This study presents the design and characterization of a photosynthetic shake flask unit, illuminated from below by warm white light‐emitting diodes with variable light intensities up to 2300 μmol m−2 s−1. The photosynthetic unit was successfully used, in combination with online monitoring of oxygen production, to cultivate Arthrospira platensis. In phototrophic growth under continuous light and a 16 h light/8 h dark cycle (light intensity: 180 μmol m−2 s−1), the oxygen transfer rate and biomass‐related oxygen production were −1.5 mmol L−1 h−1 and 0.18 mmol O2 gx−1 h−1, respectively. The maximum specific growth rate was 0.058 h−1, during the exponential growth phase, after which the biomass concentration reached 0.75 g L−1.

The challenge of scaling up photobioreactors: Modeling and approaches in small scale

Commercial large‐scale application of photobiotechnology calls for acceptable rates and high cell densities. The latter results in self‐shading and a temporally declining growth rate, making the process inefficient. Upscaling phototrophic processes requires knowledge of the reaction kinetics with special attention on the μ‐I relation. Model‐based calculations for studying the effect of self‐shading on growth were performed for three μ(I) concepts. The nonrealistic μ(I0) concept results in exponential growth without limit, the widely used μ(I(x))¯ concept exhibits a growth behavior that significantly deviates from real processes, but the sophisticated μ(I(x))¯ concept describes real processes best. A Respiration Activity Monitoring System (RAMOS) with CultiLux unit was tested regarding its applicability for exploring the μ‐I dependency of Arthrospira platensis. The results were not satisfactory because of self‐shading due to a high cell density (which was essential for yielding detectable oxygen‐evolution signals). An innovative cultivation system in which self‐shading does not interfere with phototrophic growth was required. A flat‐panel system was constructed (designed by CFD, short light path of 1 cm, uniform planar light supply by LED and OLED units), allowing continuous cultivation of phototrophic microbes at varied light intensities.