Implementation of a specific rate controller in a fed-batch E. coli fermentation

Abstract

The specific growth rate is one of the most important process variables characterizing the state of microorganisms during fermentations mainly because the biosynthesis of many products of interest is often related with the values assumed by this parameter. In the particular case of the fed-batch operation of Escherichia coli for the production of recombinant proteins, it is important to maintain the specific growth rate below a certain threshold in order to avoid the accumulation of acetic acid throughout the fermentation and, additionally, it is often argued that both pre- and the post-induction specific growth rates should be closely controlled in order to achieve maximum productivities of the desired recombinant protein. In a previous work the authors have developed and validated by simulations a strategy for the automatic control of the specific growth rate in E. coli fed-batch fermentations based on an asymptotic observer for biomass and on developed estimators for the specific growth rates. The main purpose of the present work was to implement experimentally the developed observer, estimator and controller in a real fed-batch fermentation process. For that purpose a data acquisition and control program was developed in LabVIEW that allows the acquisition of the necessary on line data (off gas and dissolved oxygen concentration and culture weight) and the calculation of the feeding rates using the developed equations. The feedforward-feedback controller developed was able to keep the culture growing in an exponential phase throughout the fermentation without accumulation of glucose and acetate.