Novel Bioreactor Designs

One of the most common forms of immobilized cell bioreactor is entrapment, where high concentrations of cells are trapped in a polymer matrix such as alginate and K-carrageenin (28,31). Thus, a high cell density is continuously retained in the fermentor while substrate is continuously converted to product. This higher concentration of biocatalysts in the reactor results in higher productivities and yields. The disadvantages of this method are migration of substrate through the matrix to the cell and the migration of product out, potentially high concentrations of product around the cells causing end product inhibition, cell leakage from the polymer matrix due to cell growth, and bead swelling and disintegration over time causing the whole fermentation to be stopped, cleaned, and restarted.

Biofilms are a natural form of cell immobilization in which microorganisms are attached to a solid surface (32). In this bioreactor, cells are continually growing, and sloughing off. Thus, the reactor is a mixture of immobilized and suspended cells. Continuous biofilm fermentations are truly open immobilized cell bioreactors (30). Their operation is equivalent to a suspended cell continuous fermentation with the added advantage of increase biomass concentrations in the bioreactor. Biofilms are typically resistant to harsh conditions, and can tolerate changes in the fermentation feed and conditions. However, not all microorganisms form biofilms. Filamentous microorganisms such as fungi and actinomycetes are natural biofilm formers. For nonfilamentous bacteria to form a biofilm, an extracellular polysaccharide needs to be generated by the bacterium (32).

Some bacteria will form biofilms on any surface such as metal, plastic, and glass. However, certain bacteria, such as lactobacilli, require something to stimulate this biofilm development (33). Plastic composite support (PCS) developed at Iowa State University has proven to stimulate biofilm development of Lactobacillus casei (22,34,36), Zymomonas mobilis (37,38), Saccharomyces cerevisiae (37,38,39), and Actinobacillus succinogenes (40). PCS is a high temperature extruded material consisting of at least 50% polypropylene, plus ground soybean hulls, bovine albumin and various culture micronutrients. Soybean hulls keep the extruded product porous due to the release of steam as the PCS leaves the extruder die. Bovine albumin performs as a natural plastizer which protects the temperature sensitive micronutrients. Micronutrients are selected based on the specific cultural requirements for amino acids, vitamins, and lipids. Monosaccharides are avoided due to poor PCS production. For example, the PCS blend for lactobacilli contains 50% (w/w) polypropylene, 35% (w/w) ground dried soybean hulls, 5% (w/w) bovine albumin, 5% (w/w) yeast extract, 5% (w/w) soybean flour, and mineral salts (35). PCS have been evaluated in batch (22), fed-batch (29), and continuous (30) lactic acid fermentations (Figure 6.3). In every application the percentage yields and productivity rates were significantly higher than suspended cell lactic acid fermentations. Furthermore, repeat batch fermentations have operated for more than 1.5 years with virtually no change in percentage yields and productivities. This longevity is attributed to the fact that once a biofilm has established on these customized materials, it will continue to grow as a biofilm. This is supported by the fact that a PCS biofilm reactor washed with concentrated ammonium hydroxide, rinsed with mineral salts solution, and then reinoculated with a fresh culture and medium will reestablish itself overnight. Commercially, the quick vinegar process is the most common biofilm process in current operation which uses wood chips for supports and Acetobacter aceti for production (27).

Solid substrate fermentation is when a substrate such as soybeans is ground, inoculated with Aspergillus oryzae, then incubated for three days for the production of soy sauce (27). It is a simple fermentation process and commonly used for aerobic fermentation due to its large surface area. Thus, oxygen concentration is high without using any mechanical forced air systems. Solid substrate fermentations require large areas or incubation space. A temperature controlled environment, intermittent monitoring for contamination and quality of starting material is essential for success.

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