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Biotechnology processes

Substrate
Raw materials

Up
Stream

Down
Stream

Microorganism
Biological system

Specific
conditions

Product

Improvement of product quality and


quantity by manipulating the process.
I- Upstream manipulation (Strain development) The
productivity of the wild strains are usually too low for
economical processes In general such programs include
Selection of the biological entities by a screening program
to choose the best biocatalyst of the required product.
Utilization of mutation techniques to prepare mutants of
better characters.
Utilization of recombinant DNA (genetic engineering) to
improve an existing process or developing a totally new
product.
Cell fusion for the generation of hybrids with improved
productivity.
Plant cell and tissue culture.

II- Down stream processing


1) Manipulation of the fermentation conditions to specify the
product and maximize the yield e.g. changing the oxygen
potential of growth for Saccharomyces yields different
product.
Saccharomyces + Hexoses aerobic
Bakers yeast
Saccharomyces + Hexoses anaerobic
alcohol
Saccharomyces + Hexoses anaerobic & bisulphite glycerol
Also citric acid production could be performed by surface or by
submerged culture (Higher yield).
2) Obtaining mathematical models for the fermentation
parameters to in the prediction of the best conditions for
maximum yield and cost reduction in scaling up of the
process.
3) Improvement of the efficiency of the biocatalyst by
immobilization (discussed later).
4) Application of the proper methods for separation and
purification of the product e.g. centrifugation, filtration or
chromatography.

Substrate
Raw materials

Up
Stream

Down
Stream

Microorganism
Biological system

Specific
conditions

Product

Fermentation processes
Fermentation is an industrial process utilizing
living cells for the production of commercially
valuable products either aerobically or
anaerobically.
In fermentation living cells are allowed to grow under
defined conditions in a fermenter (bioreactor). The
defined conditions include the use of the proper
substrate (medium) and the proper environmental
parameters (e.g. temperature, agitation, pH and
aeration).
All must be optimized to achieve the highest yield
and quality at the lowest cost possible.

Compressor

Air filter

Motor
power
unit

Inlets
Monitors

Outlets
Air exhaust
sampler
Agitator shaft

Baffle
Cooling or
heating coils

Impeller

Air sparger at
the end of air
line

Classification of bioreactors:
1. Configuration:
1. Open
2. Closed

2. Biomass retention mode:

1. Suspended

2. Immobilized

3. Flow within the bioreactor:

1. Well mixed

2. Plug flow

4. Feeding mode = common


methods of fermentation

Methods of fermentation
Batch fermentation:
Fed-batch process:
Continuous Fermentation
chemostat, or turbidostat.

Scale-up:
It is the transfer of small scale laboratory fermentation to an
industrial large scale. Fermentation processes are usually
developed in three stages namely laboratory scale (flasks,
laboratory fermenters), pilot plant scale (usually 50-200 liters)
and production scale

The scheme of fermentation process


preparation Step: Inoculum, medium & bioreactor
Production of the product: 5-10% v/v
Recovery of the product:

In most cases, the product represents a very small


fraction of the total fermentation broth and
extensive purification procedures must be
employed.

The choice of the operations used in recovery


depends on:

The nature of the desired product


Concentration
Stability
Required level of purity in the end product.

The following are the general methods for


concentration and or purification of the
product:
Centrifugation for separation of cells.
Filtration or sedimentation for separation
of cells.
Precipitation
Extraction with solvents.
Chromatography.
Fractional distillation.
Ultrafiltration.
Reverse osmosis and dialysis.

Categories of products
1. Biomass:
2. Enzyme:
3. Metabolites: either primary metabolite such as citric acid
which are usually produced during the logarithmic
phase of growth (trophophase) or secondary
metabolites such as antibiotics, alkaloids or glycosides
which are produced during the stationary phase
(idiophase).
4. Biotransformation product:
5. Biodegradation product:
6. Immunological product:
7. Energy: alcohol, methane (biogas).
8. Genetically engineered therapeutic protein:
9. Intra or extracellular accumulation of metals.
10. Plant tissue culture: cell suspension, callus and hairy
root.

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