Repeated Fed-Batch Microorganism Culture Method
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Solution Overview
Problem
Conventional batch and fed-batch microorganism fermentation processes are limited by high turnaround times and energy consumption, which restricts the operational hours of production vessels and increases costs, while continuous cultures are difficult to maintain for large-scale production.
Innovation Solution
A repeated fed-batch process where a portion of the culture is harvested and fresh medium is added to maintain a constant volume, allowing for continuous operation with a residual volume of 40% or less, reducing the need for frequent sterilization and seed train production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional batch or fed-batch fermentation processes are used, then the fermentation can be completed with standard operating procedures, but the turnaround time between batches is long and operational hours are restricted
Solution Approach 1:
The patent implements a repeated fed-batch process where the fermentation vessel operates continuously without complete emptying and sterilization between batches. A residual volume of culture (40% or less of start volume) is retained in the vessel, allowing the next batch to begin immediately after harvesting and adding fresh medium, thereby eliminating the idle turnaround time between conventional batches
Solution Approach 2:
The patent performs preliminary sterilization of the vessel only once at the beginning of the repeated fed-batch process. The residual volume of culture retained from previous batches serves as a protective barrier, allowing subsequent batches to proceed without repeated sterilization cycles, thus maintaining continuous operation while preventing contamination
2Productivity
If conventional batch or fed-batch fermentation processes are used, then the process is simple to operate, but energy consumption is high due to frequent sterilization and seed train production
Solution Approach 1:
The patent eliminates the need for repeated sterilization and seed train production by maintaining continuous operation with residual culture volumes. The vessel is sterilized only once at the start, and the residual volume acts as a protective barrier against contamination, dramatically reducing energy consumption associated with repeated sterilization cycles and seed train maintenance
Solution Approach 2:
The residual volume of culture retained from previous batches serves multiple functions: it maintains the sterile environment, provides a seed population for the next batch, and eliminates the need for external sterilization and seed train operations. The system essentially serves itself by using its own residual culture to sustain continuous operation
3Duration of action of moving object
If continuous culture methods are used, then operational hours can be extended, but the process is difficult to maintain for large-scale production
Solution Approach 1:
The patent employs a dynamic repeated fed-batch process that combines elements of both batch and continuous culture. The culture volume dynamically adjusts between batches through harvesting and fresh medium addition, while the residual volume maintains continuous operation. This dynamic approach extends operational hours while preserving the ease of batch operation for large-scale production
Solution Approach 2:
The patent changes the operational parameter from complete batch replacement to partial volume replacement (retaining 40% or less of start volume). This parameter change allows the system to operate continuously like a continuous culture while maintaining the operational simplicity and scalability of batch processes for large-scale production
Data Source
AI summary
Provided herein are methods of culturing a microorganism. The method includes providing a container comprising one or more microorganisms and medium, wherein the microorganisms and medium form a start volume. The microorganisms and medium are cultured until the culture reaches a threshold indicator, wherein culturing comprises feeding one or more carbon sources to the culture and wherein the culture is at a threshold volume when the threshold indicator is reached. The method also includes harvesting a portion of the threshold volume to leave a residual volume that is 40% or less of the start volume and adding fresh medium to the container in an amount to return the volume of the culture to the start volume.