BIOPROCESS

PRINCIPLES

Stages in an Industrial Bioprocess

Stages for an Industrial microbial
Fermentation Process

 Strain selection
 Laboratory process development
 Pilot Scale up
 Industrial Scale up
 Fermentation Media Preperation
 Downstream process development
 Product packaging techniques
 Other Commercial consideration
 Waste Disposal
June 26, 2019 Stages in an Industrial Bioprocess
June 26, 2019 Stages in an Industrial Bioprocess
An Ideal STRAIN
 Genetic Stability
 Efficient production of target product
 Limited need for vitamins and growth factors
 Utilization of wide range of low cost substrates
 Safety, GRAS
 Ready harvesting
 Limited by products production
 Easy genetic amenability

June 26, 2019 Stages in an Industrial Bioprocess

Strain Selection

How?
 Purchase from Culture Collections
 Screening of nature circumstances
 Genetic engineering
 Mutations
 Cell biology techniques
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International Culture Collections

Strains can be purchased from Culture Center

June 26, 2019 Stages in an Industrial Bioprocess
Screening of nature circumstances

June 26, 2019 Stages in an Industrial Bioprocess

 Screening
 What is screening?

 Primary Screening
 Secondary Screening

ENRICHMENT : Anearobes in N2 Atmospheres,

Acidophiles in Extreme pH values (2-4)

TEST SYTEMS: For Amylases the test system would

be agar plates with starch, selection of colonies after
staining with iodine

June 26, 2019 Stages in an Industrial Bioprocess

 Strain Isolation SCHEME
 Soil or water sample is suspended in a definite
amount of sterile water and agitated
 The supernatant is diluted 10-1 –10-10
 Samples from this dilution are placed on culture
media and then incubated
 Single colonies from the plates are picked and
purified by restreaking
 Pure strains are maintained as agar cultures in test
tubes

June 26, 2019 Stages in an Industrial Bioprocess

 Genetic
Engineering
Incorporation into
artificial plasmids of
genes from a wide
variety of sources has
made possible the
transfer of genetic
material across
virtually any species
barrier.
Various high value
added products have
been produced from
the Genetic engineering
June 26, 2019 Stages in an Industrial Bioprocess
methods
 Mutation

Via chemical
or physical,
and biological
means

June 26, 2019 Stages in an Industrial Bioprocess

Cell Biology Techniques
 Protoplast fusion
(promote high frequencies of genetic recombinants)

 Removing the cell wall with lytic enzymes in the

presence of osmotic stabilizers.
 In the presence of fusogenic agent such as
polyethylene glycol (PEG), protoplasts are
induced to fuse and form transient hybrids or
diploids.

June 26, 2019 Stages in an Industrial Bioprocess

 Scale Up

 Shake flash Experiments

 Lab scale fermentor (5-10 L)
 Pilot scale fermentor (300-3000 L)
 Commercial fermentor (10,000-500,000 L)

June 26, 2019 Stages in an Industrial Bioprocess

A Traditional Bioprocess ( Yeast)

June 26, 2019 Stages in an Industrial Bioprocess

 F&I10

Traditional Bioprocess
DSP of Yeast Biomass
• collect cells
• wash cells
• dewater cells
• achieve desired consistency
• package
• store until shipped
DSP of cellular products Entails:
• removal of biomass from culture medium, concentration and
purification of product from spent medium
• harvesting + fractionation of biomass to recover product
separation from cell debris, concentration & purification of product
June 26, 2019 Stages in an Industrial Bioprocess
A Typical Bioprocess Flow Sheet

June 26, 2019 Stages in an Industrial Bioprocess