Respirometry is a precious tool for determining the activity of microbial populations. The measurement of oxygen uptake rate is commonly used but cannot be applied in anoxic or anaerobic conditions or for insoluble substrate. Carbon dioxide production can be measured accurately by gas balance techniques, especially with an on-line infrared analyzer. Unfortunately, in dynamic systems, and hence in the case of short-term batch experiments, chemical and physical transfer limitations for carbon dioxide can be sufficient to make the observed carbon dioxide evolution rate (OCER) deduced from direct gas analysis very different from the biological carbon dioxide evolution rate (CER).To take these transfer phenomena into account and calculate the real CER, a mathematical model based on mass balance equations is proposed. In this work, the chemical equilibrium involving carbon dioxide and the measured pH evolution of the liquid medium are considered. The mass transfer from the liquid to the gas phase is described, and the response time of the analysis system is evaluated.Global mass transfer coefficients (K(L)a) for carbon dioxide and oxygen are determined and compared to one another, improving the choice of hydrodynamic hypotheses. The equations presented are found to give good predictions of the disturbance of gaseous responses during pH changes.Finally, the mathematical model developed associated with a laboratory-scale reactor, is used successfully to determine the CER in nonstationary conditions, during batch experiments performed with microorganisms coming from an activated sludge system.

Determination of carbon dioxide evolution rate using on-line gas analysis during dynamic biodegradation experiments.

We present robust methods for online estimation of cell specific oxygen uptake and carbon dioxide production rates (q(O2) and q(CO2), respectively) during perfusion cultivation of mammalian cells. Perfusion system gas and liquid phase mass balance expressions for oxygen and carbon dioxide were used to estimate q(O2), q(CO2) and the respiratory quotient (RQ) for Chinese hamster ovary (CHO) cells in perfusion culture over 12 steady states with varying dissolved oxygen (DO), pH, and temperature set points. Under standard conditions (DO = 50%, pH = 6.8, T = 36.5°C), q(O2) and q(CO2) ranges were 5.14-5.77 and 5.31-6.36 pmol/cell day, respectively, resulting in RQ values of 0.98-1.14. Changes to DO had a slight reducing effect on respiration rates with q(O2) and q(CO2) values of 4.64 and 5.47, respectively, at DO = 20% and 4.57 and 5.12 at DO = 100%. Respiration rates were lower at low pH with q(O2) and q(CO2) values of 4.07 and 4.15 pmol/cell day at pH = 6.6 and 4.98 and 5.36 pmol/cell day at pH = 7. Temperature also impacted respiration rates with respective q(O2) and q(CO2) values of 3.97 and 4.02 pmol/cell day at 30.5°C and 5.53 and 6.25 pmol/cell day at 37.5°C. Despite these changes in q(O2) and q(CO2) values, the RQ values in this study ranged from 0.98 to 1.23 suggesting that RQ was close to unity. Real-time q(O2) and q(CO2) estimates obtained using the approach presented in this study provide additional quantitative information on cell physiology both during bioprocess development and commercial biotherapeutic manufacturing.

Estimating cell specific oxygen uptake and carbon dioxide production rates for mammalian cells in perfusion culture.

The production of monoclonal antibodies by mammalian cell culture in bioreactors up to 25,000 L is state of the art technology in the biotech industry. During the lifecycle of a product, several scale up activities and technology transfers are typically executed to enable the supply chain strategy of a global pharmaceutical company. Given the sensitivity of mammalian cells to physicochemical culture conditions, process and equipment knowledge are critical to avoid impacts on timelines, product quantity and quality. Especially, the fluid dynamics of large scale bioreactors versus small scale models need to be described, and similarity demonstrated, in light of the Quality by Design approach promoted by the FDA. This approach comprises an associated design space which is established during process characterization and validation in bench scale bioreactors. Therefore the establishment of predictive models and simulation tools for major operating conditions of stirred vessels (mixing, mass transfer, and shear force.), based on fundamental engineering principles, have experienced a renaissance in the recent years. This work illustrates the systematic characterization of a large variety of bioreactor designs deployed in a global manufacturing network ranging from small bench scale equipment to large scale production equipment (25,000 L). Several traditional methods to determine power input, mixing, mass transfer and shear force have been used to create a data base and identify differences for various impeller types and configurations in operating ranges typically applied in cell culture processes at manufacturing scale. In addition, extrapolation of different empirical models, e.g. Cooke et al. (Paper presented at the proceedings of the 2nd international conference of bioreactor fluid dynamics, Cranfield, UK, 1988), have been assessed for their validity in these operational ranges. Results for selected designs are shown and serve as examples of structured characterization to enable fast and agile process transfers, scale up and troubleshooting.

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Equipment characterization to mitigate risks during transfers of cell culture manufacturing processes

Monitoring off-gas O2/CO2 to predict nitrification performance in activated sludge processes.

The effect of two inhibiting substrates on growth kinetics and cell maintenance of the yeast Candida valida

The total amount of carbon dioxide (CD) produced by a microbial culture is evolved via an outlet gas stream, outflowing broth, and can lead to a rise of the CD content in broth. To analyze relations among the three amounts, the equilibrium is considered between different ionic forms of carbon dioxide at different pH values as well as between the gaseous and disolved CO2. Dependences of the equilibrium constants on temperature are found by a thermodynamic analysis. Numerical estimation of an error of the CD production rate measurement, originating from the neglect of dissolved CD, is developed. The gas analysis technique alone provides a sufficient accuracy at pH lower than 6. At higher pH the error can be estimated using equations presented below.

Influence of carbon dioxide solubility on the accuracy of measurements of carbon dioxide production rate by gas balance technique

The given paper represents formulae for calculation of oxygen consumption and of carbon dioxide formation in a microbial culture obtained from corrected measuring data of gas balance measurements. Basic relations between these measuring data the respiration quotient RQ were derived. The influence of measuring error to the accuracy of determination of oxygen consumption and of carbon dioxide formation at the analysis of gas concentrations and of air flow is discussed. It is shown that the determination of carbon dioxide formation rate is possible in many cultivation regimes with better accuracy than the determination of oxygen uptake rate.

Microbial gas balance measurements: Basic interrelations and error estimation

The experimental technique for measurement of microbial culture heat evolution directly in fermenter has been described and its correctness analysed. Heat-to-oxygen ratio, Q0, of synchronized yeast culture in the absence of fermentative metabolism has been found to be practically independent of a cell cycle phase and close to the theoretical constant predicted by the mass-energy balance theory. The collection of literature data on the heat-to-oxygen ratio is given. Energetic properties of cell biomass are discussed on the basis of the obtained and the surveyed values of Q0.

Ratio of heat production to oxygen consumption during the cell cycle of candida maltosa EH 15 grown on ethanol

The dynamics of pH-controlled chemostat and pH-auxostat is considered. The medium flow governed by pH-controller is calculated using the ionic (mass-charge) balance equations. The generalized equations of pH-controlled continuous fermentation are developed for the case of two variables: cell biomass and residual substrate concentrations. The study of steady state solutions has shown a substantial dependence of the variable patterns on a concentration of alkali (or acid) in titrant medium flow. The generalized analytical expressions for eigenvalues (reciprocals of transient characteristic times) of the culture dynamics have been obtained. The rates of transients during the steady state establishment are considered using these eigenvalues.

The effect of automatic ph maintenance on steady state cultivation regimes and their stability. A theoretical study of the case of a perfect ph controller and perfect stirring

I. G. Minkevich

Papers

Influence of carbon dioxide solubility on the accuracy of measurements of carbon dioxide production rate by gas balance technique

Microbial gas balance measurements: Basic interrelations and error estimation

Ratio of heat production to oxygen consumption during the cell cycle of candida maltosa EH 15 grown on ethanol

The effect of automatic ph maintenance on steady state cultivation regimes and their stability. A theoretical study of the case of a perfect ph controller and perfect stirring