BIOPROCESSING

Week 3
 Definition
Another way to describe manufacturing
Bioprocessing is the use of biological
materials (organisms, cells, organelles,
enzymes) to carry out a process for
commercial, medical or scientific reasons

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 Industrial Fermentation
Upstream processing (USP)
all factors and processes leading to, and
including the fermentation
Downstream processing (DSP)
encompasses all process following the
fermentation

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 UPS
Producer microorganism
Isolation, strain improvement, strain purity,
suitable inoculum
Fermentation Media
Selection of suitable cost effective carbon,
energy, electron source and micronutrients
Controlled Conditions
Optimize the growth of the organism,
production of a target microbial product
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 DSP
Aims: for efficiently, reproducibly and safely
recovering the product
Maximizing recovery yield and minimizing cost
Primary recovery
Product Purification
Finishing Processes

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Typical unit processes in DSP

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 Cell Harvesting
Broth conditioning
Mostly used in association with sedimentation
and centrifugation for separation of cells from
LM
Sedimentation
Used for primary yeast separation production
of alcoholic beverages
Suitable for large flocs greater than 100m
diameter
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 Centrifugation
Using gravitational force to separate suspended
particles.
Used to separate particle as small as 0.1m
diameter and for some liquid-liquid separation.
Depends on particle size, density difference
between the cells and the medium, and medium
viscosity.
Can divided into small scale laboratory units and
larger pilot and industrial scale
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Type of Industrial Centrifuge
Tubular : 13.00-17.000g, periodic removal of solids

Multichamber bowl: 5000-10000g, smaller particles

collect in the outer chambers

Disc stack: 5000-13000g , have the facility to

discharge the collected material periodically during
operation

Screw decanter: 1500-5000g, suitable for dewatering

coarse solid materials at high solids concentration, for
harvesting yeast and fungal mycelium

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 Filtration
Useful for harvesting filamentous fungi, but are
less effective for collecting bacteria
1. Plate and Frame filters used for harvesting
MO from fermentations
2. Rotary Vacuum filters simple continous
filtration systems for harvesting fungal
mycelium during antibiotic manufacture

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 Cell Disruption
Required to disrupt the MO and release the
product
1. Mechanical cell disruption methods
High pressure homogenizer, ultrasonic/
Sonication
2. Non mechanical cell disruption methods
By autolysis, osmotic shock, rupture with ice
crystal (freezing) or heat shock.
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 Product Purification
Chromatography
Employed for higher-value products, involving columns
of chromatographic media used for desalting,
concentration and purification protein
The parameter:
1. Capacity the sample size in terms of protein
concentration and volume
2. Recovery the yield of product at each stage
3. Resolving power ability to separate two
component (product and impurity)
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 Distillation
Used to recover fuel
alcohol, acetone, and
other solvents from
fermentation media and
for the preparation of
potable spirits.

Source: Industrial Microbiology, an

introduction, 2001

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 Finishing steps
Crystallization
By evaporation, low temperature treatment or
addition of a chemical reactive with the solute.
Ex: salts, solvents
Drying
Involves the transfer of heat to the wet material
Removal of the moisture as water vapour
By direct contact, convection, radiation
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 Freeze drying (lyophilization)
Useful for some enzymes, vaccines, and other
pharmaceuticals.
The water is removed by sublimation under
vacuum.
Eliminates thermal and osmotic damage

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THE END

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