Optimization of pullulan production from synthetic medium by Aureobasidium pullulans in a stirred tank reactor by response surface methodology

The production of pullulan from synthetic medium by Aureobasidium pullulans P56 in a stirred tank fermenter was investigated. The kinetics of polysaccharide, pullulan and biomass production was determined. Response surface methodology was used to investigate the effects of three factors (initial sugar concentration, aeration rate and agitation speed) on the concentration of pullulan in batch cultures of A pullulans. In the experiments, the range of values used for the three variables described were; 30–70 g dm^?3 initial sugar concentration, 200–600 rpm agitation speed and 1.0–3.0 vvm aeration rate. No previous work has used statistical analysis in determining the interactions among these variables in pullulan production. Results of the statistical analysis showed that the fit of the model was good in all cases. Aeration rate, agitation speed and sugar concentration had a strong linear effect on pullulan concentration. Moreover, pullulan concentration was significantly influenced by the negative quadratic effects of the given variables and by their positive or negative interactions with the exception that the interaction between agitation speed and aeration rate was insignificant (P > 0.05). Maximum pullulan concentration of 17.2 g dm^?3 was obtained at the optimum levels of process variables (initial sugar concentration 51.4 g dm^?3, aeration rate 2.36 vvm, agitation speed 345.3 rpm). These values were obtained by fitting of the experimental data to the model equation. Scanning electron microscope (SEM) photographs of polysaccharide particles containing different concentrations of pullulan were also taken to observe the morphological differences of the samples. Copyright © 2005 Society of Chemical Industry     

A comprehensive study of lipase production by Yarrowia lipolytica CECT 1240 (ATCC 18942): from shake flask to continuous bioreactor

BACKGROUND: Lipases are commercially important enzymes, and the development and optimization of their production processes are of great interest. The diversity of behaviours between strains stresses the need for research on this topic, especially when bioreactor culture is considered. The study of a continuous operating mode is especially attractive, since very scarce information is available on its application to microbial lipases production. RESULTS: Lipase production in submerged cultures of Yarrowia lipolytica CECT 1240 (ATCC 18 942) has been investigated. Significant lipolytic activity (over 700 U dm^?3), mostly extracellular and membrane‐bound, was obtained in shake flasks using medium supplemented with olive oil. The culture was carried out in air‐lift and stirred tank bench‐scale bioreactors and the latter was selected. The influence of aeration and agitation rates was assessed in batch cultures, and agitation from 400–700 rpm and low aeration rates (i.e. 0.2 vvm) are recommended. Batch, fed‐batch and continuous operation were investigated, and regular enzyme production (up to 600 U dm^?3) was achieved with the latter. CONCLUSION: Lipase production by the selected strain was successfully carried out in shake flasks and bench‐scale bioreactors. After studying batch, fed‐batch and continuous processes, continuous culture in a stirred tank bioreactor was found best in terms of regular enzyme production, exceptionally good operational stability and good fitting of the results to mathematical models. Copyright © 2009 Society of Chemical Industry     

Comparison of lipase production by Geotrichum candidum in stirring and airlift fermenters

The production of lipase by Geotrichum candidum in both, stirred tank and airlift bioreactors were compared. G candidum an imperfect filamentous fungus, grows well in liquid medium, and produces a lipase with specific affinity for long‐chain fatty acids with cis‐9 double bonds but, lipase production is generally not efficient because the optimum medium composition and fermentation conditions are not known. Response surface methodology was used to optimize the agitation speed (100–500 rpm) and aeration (0.2–1.8 vvm) for production of lipase by G candidum in a bench‐scale stirred fermenter. A Central Composite Rotatable Design (CCRD) was used to optimize lipase activity and productivity. Lipase production in an airlift fermenter was also studied with aeration ranging from 1 to 3 vvm. A previously optimized culture medium containing 3.58% of peptone, 0.64% of soy oil and an initial pH of 7.0, was used in the experiments, incubating at 30°C. In the stirred reactor the optimum conditions of agitation and aeration for lipase production and productivity were 300 rpm and 1 vvm, leading to an activity of 20 U cm^?3 in 54 h of fermentation and 0.3900 (U cm^?3 h^?1) of productivity. The best aeration condition in the airlift fermenter was 2.5 vvm, which yielded similar lipase activity after 30 h of fermentation, resulting in a productivity of 0.6423 (U cm^?3 h^?1). In the absence of mechanical agitation similar lipase yields were achieved but in less time, resulting in productivity, about 60% greater than in a stirred fermenter; the lower energy demand for the same lipase yield offers economic advantages. Copyright © 2004 Society of Chemical Industry     

Aeration and mixing in vortex fermenters

The overall apparent volumetric gas—liquid mass transfer coefficient (k₉₅a) and the mixing time (t₉₅) were determined in a 240 dm³ vortex aerated fermenter over stirrer speed and air flow ranges of 300–800 rpm and 10–45 normal dm³ min^?1, respectively. The mass transfer data obtained in an aqueous salt solution (2.5 kg m^?3 NaCl in water) compared well with the measurements in a fermentation medium used in culture of certain microaerophilic bacteria. Over the ranges examined, the gas-liquid mass transfer coefficient depended only on air flow rate; the dependence was linear with flow. Mixing time declined with increasing agitation according to a power-law relationship. The mixing and mass transfer characteristics of the vortex aerated system were compared with that of a ‘standard’ stirred tank fermenter (27 dm³). The mixing time variations with respect to agitation rate were remarkably similar for the two types of fermenters examined.     

Optimization of the production of β‐carotene from molasses by Blakeslea trispora: a statistical approach

The effect of pretreatment of molasses, nitrogen sources, natural oils, fatty acids, antioxidant, precursors, and mixtures of the above substances on β‐carotene production by Blakeslea trispora in shake flask culture was investigated. Also, a central composite design was employed to determine the maximum β‐carotene concentration at optimum values for the process variables (linoleic acid, kerosene, antioxidant). The highest concentration of the carotenoid pigment was obtained in molasses solution treated with invertase. Corn steep liquor and yeast extract at concentrations of 5.0% and 0.5% (w/v), respectively, increased slightly the concentration of β‐carotene, while the natural oils, fatty acids, and precursors (except kerosene) did not improve the production of pigment when they were added separately to the medium. On the other hand, the mixture of linoleic acid, kerosene and antioxidant increased significantly the concentration of β‐carotene. The fit of the model was found to be good. Linoleic acid, kerosene and antioxidant had a strong linear effect on β‐carotene concentration. The concentration of β‐carotene was significantly affected by linoleic acid–antioxidant and kerosene–antioxidant interactions as well as by the negative quadratic effects of these variables. The interaction between linoleic acid–kerosene had no significant linear effect. Maximum β‐carotene concentration (790.0 mg dm^?3) was obtained in culture grown in molasses solution supplemented with linoleic acid (30.74 g dm^?3), kerosene (27.79 g dm^?3) and antioxidant (10.22 g dm^?3). © 2002 Society of Chemical Industry     

The effect of fermentation parameters on the production of Mucor miehei acid protease in a chemically defined medium

Batch shake flask experiments were carried out with a fungal strain of Mucor miehei ATCC 3420 to study the effects of five fermentation parameters; initial D ‐glucose concentration, temperature, initial pH, agitation rate and inoculum ratio, on the production of rennin in a chemically defined medium. A statistical design was used to assign the experimental levels of five fermentation parameters for the determination of optimum conditions. The highest concentration of milk‐clotting activity (MCA) obtained was 2286 SU cm^?3 (without concentration of the broth) at 29.6 g dm^?3 initial D ‐glucose concentration, 6.8 initial pH, 37.6 °C temperature, 81 stroke per min agitation rate and 5.2% (v/v) inoculum ratio. Although enzyme secretion was a function of all the operational parameters investigated, the pH range (4.6–5.2) reached at the time of enzyme production had a profound effect on milk‐clotting activity levels. In the fermentation sample at maximum milk‐clotting activity the R factor, the ratio of milk‐clotting activity to proteolytic activity, was determined as 1 SU PU^?1, denoting similar characteristics to a commercial animal rennet. © 2001 Society of Chemical Industry     

Optimization of lactic acid production from whey by L casei NRRL B‐441 immobilized in chitosan stabilized Ca‐alginate beads

The production of lactic acid from whey by Lactobacillus casei NRRL B‐441 immobilized in chitosan‐stabilized Ca‐alginate beads was investigated. Higher lactic acid production and lower cell leakage were observed with alginate–chitosan beads compared with Ca‐alginate beads. The highest lactic acid concentration (131.2 g dm^?3) was obtained with cells entrapped in 1.3–1.7 mm alginate–chitosan beads prepared from 2% (w/v) Na‐alginate. The gel beads produced lactic acid for five consecutive batch fermentations without marked activity loss and deformation. Response surface methodology was used to investigate the effects of three fermentation parameters (initial sugar, yeast extract and calcium carbonate concentrations) on the concentration of lactic acid. Results of the statistical analysis showed that the fit of the model was good in all cases. Initial sugar, yeast extract and calcium carbonate concentrations had a strong linear effect on lactic acid production. The maximum lactic acid concentration of 136.3 g dm^?3 was obtained at the optimum concentrations of process variables (initial sugar 147.35 g dm^?3, yeast extract 28.81 g dm^?3, CaCO₃ 97.55 g dm^?3). These values were obtained by fitting of the experimental data to the model equation. The response surface methodology was found to be useful in optimizing and determining the interactions among process variables in lactic acid production using alginate–chitosan‐immobilized cells. Copyright © 2005 Society of Chemical Industry     

Kinetics of Lactic Acid Fermentation by Lactobacillus delbrueckii Grown on Beet Molasses

The fermentation kinetics for the conversion of beet molasses, a valuable and economical fermentation substrate, to lactic acid by the homofermentative organism Lactobacillus delbrueckii C.E.C.T. 286 have been studied at controlled pH and temperature under anaerobic batch conditions. An inhibitory effect of lactic acid on fermentation of beet molasses has been found. The bacterium was able to produce lactic acid even after growth ceased. A kinetic model for the fermentation is proposed. From this model, the maximum allowable lactic acid concentration above which growth stops and the lactic acid level above which bacteria stop producing lactic acid were found to be 45 g dm⁻³ and 57 g dm⁻³, respectively. © 1997 SCI.     

Some aspects of homogeneous and two-phase aromatic sulphonation

The two-phase sulphonation of benzene and toluene with concentrated sulphuric acid solutions at 30°C has been studied in a continuous stirred tank reactor (1.06 dm³ capacity). The rates of reaction, as a function of sulphuric acid concentration and the overall mass transfer coefficient times, and the interfacial area per unit volume of the acid phase as a function of agitation speed, have been determined. In homogeneous systems, the kinetic rate constants and the relative rates of sulphonation of a series of aromatic hydrocarbons have been measured in the range of 13–16 mol dm^?3 sulphuric acid. It has been shown that the rates of sulphonation of compounds, with levels of reactivity beyond that of m-xylene, are likely to be affected by diffusional phenomena.     

Production of the fungal exopolysaccharide scleroglucan by cultivation of Sclerotium glucanicum in an airlift reactor with an external loop

Sclerotium glucanicum NRRL 3006 was cultivated in a 120 dm³ working volume airlift reactor with external recirculation loop for the production of the exopolysaccharide (EPS), scleroglucan. When culture pH was not controlled EPS production, at a range of air flow rates, was poor (<2 kg m^?3). Biomass formation generally increased with increasing aeration rate. When culture pH was controlled at 4·5 ± 0·2 EPS production was maximal at an air flow rate of 100 dm³ min^?1 and fell as air flow rate decreased. Operation of the reactor at a high (100 dm³ min^?1) air flow rate for the early part of the process (up to 96 h), followed by a low air flow rate (20 dm³ min^?1), led to reduced biomass and oxalate formation, and a slight increase in EPS concentration relative to operation at a constant air flow rate of 100 dm³ min^?1. EPS production in this pneumatically-agitated reactor was equal to the highest levels reported in small-scale stirred tank reactors.     

Batch production of L(+) lactic acid from whey by Lactobacillus casei (NRRL B‐441)

The effects of temperature, pH, and medium composition on lactic acid production by Lactobacillus casei were investigated. The highest lactic acid productivity values were obtained at 37 °C and pH 5.5. The productivity was 1.87 g dm^?3 h^?1 at 37 °C in shake flasks. In the fermenter, a productivity of 3.97 g dm^?3 h^?1 was obtained at pH 5.5. The most appropriate yeast extract concentration was 5.0 g dm^?3. Whey yielded a higher productivity value than the analytical lactose and glucose. Initial whey lactose concentration did not affect lactic acid productivity. MnSO₄ ·H₂O was necessary for lactic acid production by L casei from whey. Product yields were approximately 0.93 g lactic acid g lactose^?1. Copyright © 2004 Society of Chemical Industry     

Influence of Aerobic Pretreatment with Penicillium decumbens on the Anaerobic Digestion of Beet Molasses Alcoholic Fermentation Wastewater in Suspended and Immobilized Cell Bioreactors

A comparative study was carried out on the anaerobic digestion of untreated and previously-fermented (with Penicillium decumbens) beet molasses. Four continuous stirred tank reactors were used for the study, two with freely suspended biomass, and the other with biomass supported on saponite. The reactors operated satisfactorily between hydraulic retention times (HRT) of 53·3–10·6 days and 15·4–3·1 days for untreated and previously-fermented molasses respectively. The anaerobic digestion processes of untreated and pretreated molasses were found to follow first-order kinetics for biomass loading rates in the range of 0–0·55 and 0–0·75 g chemical oxygen demand (COD) g⁻¹ volatile suspended solids (VSS) day⁻¹ respectively. The experimental data [namely unitary conversion or efficiency (X), HRT, biomass concentration (M) and incoming substrate concentration (S₀)] conformed to an equation of the form: X/HRT = KM(1-X)–(KMS_R/S₀), from which the kinetic constant, K, was calculated. The kinetic constants were influenced by the pretreatment carried out and were 1·7 and 2·5 times higher for pretreated molasses than for untreated molasses in the reactors with suspended and immobilized biomass respectively. This was significant at a 95% confidence level. The specific rate of substrate uptake for cell maintenance (m) decreased by a factor of approximately 2 for the previously fermented molasses in relation to the observed values for the untreated molasses. This may be attributable to the fact that higher phenolic compound concentrations inhibit and interfere with the activity of anaerobic bacteria. © 1997 SCI.     

Determination of agitation and aeration conditions for scale-up of cellulolytic enzymes production by <Emphasis Type="Italic">Trichoderma inhamatum</Emphasis> KSJ1

10 to 35 L jar fermentation scale-up cultures were performed to determine the optimum agitation and aeration rates in the cellulolytic enzymes production culture by Trichoderma inhamatum KSJ1. The optimum agitation rate in the 35 L jar fermenter was provisionally determined to be 150 rpm by using a geometrically resembled scale up method from the 10 L jar fermenter. The optimum aeration rate was determined to be 0.5 vvm by applying the mean values of superficial velocity and vvm. The DO (Dissolved Oxygen) concentration of the culture liquid was maintained below the critical DO concentration (2.336 mg/L) at 150 rpm in the 35 L jar fermenter. To increase the DO above the critical DO concentration, the agitation rate was increased from 150 to 200 rpm, with the aeration rate maintained at 0.5 vvm. As a result, the DO was maintained above critical DO concentration. The OUR (Oxygen Uptake Rate) and k _L a values were 0.91 mg-DO/L·min and 11.1 hr⁻¹, respectively. The amylase and FPase (filter paper activity) activities were 4.48 and 0.74 U/mL, respectively, in the 35 L jar fermenter, which was comparable to that in the 10 L fermenter (4.2 and 0.5 U/mL, respectively). Therefore, the scale-up conditions, 0.5 vvm and 200 rpm, were concluded to be the optimum aeration and agitation rates in the 35 L jar fermenter.     

Production of delta‐endotoxin by Bacillus thuringiensis subsp kurstaki and overcoming of catabolite repression by using highly concentrated gruel and fish meal media in 2‐ and 20‐dm3 fermenters

Delta‐endotoxin production by a strain of Bacillus thuringiensis subsp kurstaki exhibiting larvicidal toxicity towards lepidoptera was investigated in 2‐ and 20‐dm³ fermenters, using gruel‐ and fish meal‐based media. The results show clearly that in such complex media, aeration plays an important role in bioinsecticide production. Optimal aeration led to improvement of delta‐endotoxin concentrations with decreases of final spore count and proteolytic activity. Moreover, in order to use high gruel concentrations, a fermenter configuration with an efficient aeration system should be used. In a 20‐dm³ Biolafite fermenter, 59 g dm^?3 or 75 g dm^?3 gruel was used to produce bioinsecticides with a significant reduction of carbon catabolite repression of delta‐endotoxin synthesis. This result is very interesting in order to produce high final delta‐endotoxin concentrations in the culture broth. It was also concluded, by considering the key role of oxidative pathways in delta‐endotoxin synthesis, that oxygen supply must be adequate for bioinsecticide production at high substrate concentrations. Moreover, the role of sodium chloride in improving delta‐endotoxin production is dependent not only on protease synthesis and its effect on crystal stability, but also on the aeration level of the production medium. © 2002 Society of Chemical Industry     

Batch and Continuous Production of Lactic Acid from Beet Molasses by Lactobacillus delbrueckii IFO 3202

Process variables were optimized for the production of lactic acid from pretreated beet molasses by Lactobacillus delbrueckii IFO 3202 for batch and continuous fermentations. In the batch fermentation, maximum yields (95·4% conversion, 77·1% effective) and maximum lactic acid volumetric productivity (4·83 g dm⁻³ h⁻¹) was achieved at 45°C, pH 6·0, 78·2 g dm⁻³ sugar concentration with 10 g dm⁻³ yeast extract. Various cheaper nitrogen sources were replaced with yeast extract on equal nitrogen bases in batch fermentation. Of all the nitrogen sources tested, yeast extract yielded the highest and malt sprouts yielded the second highest level of lactic acid. In the continuous fermentation, maximum lactic acid (4·15%) was obtained at a dilution rate of 0·1 h⁻¹. Maximum volumetric lactic acid productivity (11·20 g dm⁻³ h⁻¹) occurred at D = 0·5 h⁻¹ dilution rate. © 1997 SCI.     

In‐line mixing for production of citric acid by Candida lipolytica grown on n‐paraffins

This study reports on the effects of internal fermenter and external in‐line agitation and fed‐batch mode of operation on citric acid production from Candida lipolytica using n‐paraffin as the carbon source. An optimum range of fermenter agitation speeds in the range 800–1000 rpm corresponding to Reynolds numbers of 50433–62947 (based on initial batch conditions) seemed to give the best balance between substrate utilization for biomass growth and citric acid production. Proof of concept evidence is presented that indicates that an external in‐line agitator could be used in place of high speed internal agitation to increase citric acid production. However, more work is required to optimize the external agitator concept. Application of multiple fed‐batch feedings can be used to extend the batch fermentation and increase final citric acid concentrations and product yield. Experiments were conducted implementing a three‐cycle fed‐batch process which increased overall citric acid yields to 0.8–1.0 g citric acid g^?1 n‐paraffin, approximately 200% improvement from those found in the normal batch process. The three‐cycle fed‐batch mode of operation also increased the final citric acid concentration to 42 g dm^?3 from about 6 g dm^?3 for normal batch operation. Increased citric acid concentrations in three‐cycle fed‐batch mode was achieved at longer fermentation times. Copyright © 2004 Society of Chemical Industry     

High density culture of Coptis japonica cells increases berberine production

A high density culture method was devised to improve the yield of berberine from highly productive cells of Coptis japonica. By adjusting aeration and stirring, Coptis cells were cultured at densities of up to 75 g dm^?3 (dry weight) in a culture tank fitted with a hollow-paddle type stirrer. Whereas a maximum density of 30 g dm^?3 of C. japonica cells could be used in ordinary batch culture, 48 g dm^?3 could be used in a fed-batch culture in which the amounts of the nutrients in the medium were made proportional to the density of the inoculum. Moreover, in fed-batch culture done with modified medium, the composition of which had been determined from the amounts of components incorporated in cells grown at the usual density for ordinary batch culture, the cell yield was improved to 55 g dm^?3 and the berberine yield to 3.5 g dm^?3.     

Combined Effect of Agitation/Aeration and Fed‐Batch Strategy on Ubiquin‐ one‐10 Production by Pseudomonas diminuta

The effects of aeration rate and agitation speed on ubiquinone‐10 (CoQ10) submerged fermentation in a stirred‐tank reactor using Pseudomonas diminuta NCIM 2865 were investigated. CoQ10 production, biomass formation, glycerol utilization, and volumetric mass transfer coefficient (k_La) were affected by both aeration and agitation. An agitation speed of 400 rpm and aeration rate of 0.5 vvm supported the maximum production (38.56 mg L^–1) of CoQ10 during batch fermentation. The fermentation run supporting maximum production had an k_La of 27.07 h^–1 with the highest specific productivity and CoQ10 yield of 0.064 mg g^–1h^–1 and 0.96 mg g^–1 glycerol, respectively. Fermentation kinetics performed under optimum aeration and agitation showed the growth‐associated constant (a = 5.067 mg g^–1) to be higher than the nongrowth‐associated constant (β = 0.0242 mg g^–1h^–1). These results were successfully utilized for the development of fed‐batch fermentation, which increased the CoQ10 production from 38.56 mg L^–1 to 42.85 mg L^–1.     

Improved Ethanol Production by Saccharomyces cerevisiae with EDTA,Ferrocyanide and Zeolite X Addition to Sugar Beet Molasses

The influence of ethylenediaminetetra acetic acid (EDTA), potassium ferrocyanide and zeolite X on ethanol production from sugar beet molasses by Saccharomyces cerevisiae was studied. For all of the three substances used, the effect was more pronounced when added to the fermentation medium rather than to the growth medium; 1·9 mmol dm⁻³ potassium ferrocyanide caused an increase in the final ethanol concentration of about 16·4% and 47·5% with respect to control culture on addition to growth and fermentation media respectively. The greatest stimulation in product yield was obtained with zeolite X introduced during the fermentation stage; 8·0 g dm⁻³ zeolite X increased ethanol concentration by 53·3%. © 1997 SCI.     

Assessment of Relevant Factors Influencing Lipolytic Enzyme Production by Thermus thermophilus HB27 in Laboratory‐Scale Bioreactors

Nowadays, there is not much information on the large‐scale production of thermostable lipolytic enzymes by thermophilic organisms. Therefore, in this study the lipolytic enzyme production by Thermus thermophilus HB27 in laboratory‐scale bioreactors was undertaken. In order to determine the most suitable bioreactor, two configurations were investigated: stirred‐tank and airlift bioreactor. It was demonstrated that the stirred‐tank configuration led to the highest lipolytic extracellular activities, about 2.3‐fold higher than those found in the corresponding cultivation in the airlift bioreactor. On the other hand, the influence of several factors such as culture nutrients concentration, aeration, and agitation rate on the production of thermophilic lipolytic enzymes in a 5‐L stirred‐tank bioreactor was assayed. At reduced nutrients concentration (50 % with respect to the basal medium), a higher product/biomass yield was attained, without any operational problems. From the relationship between mass transfer coefficient (K_La), aeration, and agitation rates it was concluded that there is a lesser dependence on the aeration than the agitation rate. In addition, the mechanical stirring of the bioreactor could tear the membranes that contain the rotund bodies often found in cultures of thermophilic microorganisms, thus increasing the extracellular enzyme production.