Bioprocessing is the method by which natural features of living organisms are used to create products. Upstream and downstream bioprocessing are the two main stages of bioprocessing. These processes make use of the knowledge bases of various scientific forms of study, and used together result in the production of high-quality items. Bioprocessing methods are used in various industries, and in this article we’ll discuss batch, fed-batch, and continuous fermentation – the main bioprocess modes.
Batch Fermentation
The batch fermentation process consists of putting microorganisms into a fermenter and nurturing them using a nutrient-rich medium. As it grows, the microorganism slowly takes in nutrients, causing the cultural environment to keep changing. Microbial growth takes place over a series of important stages.
- Lag Phase
- Exponential Growth Phase
- Stationary Growth Phase
- Death Phase
During the initial lag phase, the organism both multiplies, and changes to its new setting at the same time. Growth is at its slowest during this phase.
This is followed by an exponential growth phase, where growth occurs at an increased and more stable rate. As the amount of nutrients available reduces, growth also slows. Generally, it is not until the stationary growth phase that the culture is harvested.
After microorganisms go through a purification process they can be used to make products, such as medications. Methods such as freeze-drying and spray-drying are usually implemented to enhance API retention and reduce molecular degradation. Microorganisms will then enter a death phase if they are allowed to continue to grow. In this phase, cell density reduces drastically.
Fed-batch Fermentation
Batch fermentation is similar to fed-batch fermentation in many ways. However, this process differs in the sense that nutrients are gradually added to the culture during the growth phases. This bioprocessing method is the most common and in the exponential growth phase, it optimises biomass accumulation.
Continuous Fermentation
This method consists of bioprocess engineers continuously adding fresh medium to the fermenter while harvesting cells at the same time. When this takes place, depleted nutrients are replaced and toxic metabolites are removed from the growth environment. The culture environment and cellular growth rate can be stabilised by engineers if the medium exchange rate is controlled. Cultures can grow for days, weeks, or months if a stable state is upheld.
The Art of Bioprocessing
An integral part of bioprocessing is living organisms. They provide scientists with the raw materials necessary to develop valuable products. In some instances, entire organisms are used whereas in other instances only individual cells or portions of an organism are used.
Upstream Bioprocessing
Upstream bioprocessing is the first stage of bioprocessing. It is at this stage that organisms are detected and harvested from nature or artificially cultivated in labs. Depending on how it is being applied, the upstream process varies drastically.
Media preparation, and bioreactor and incubator usage multiplies microbes in the upstream phase.
The Role of Bioprocess Engineering
Bioprocess engineering can be categorised as upstream bioprocessing. It involves nurturing environments in a way that stimulates the growth of relevant organisms. This is done to be able to constantly achieve a particular sum of quality organisms that are not costly. The role of bioprocessing is extremely crucial in terms of commercialising products. It allows labs to increase production while still satisfying consumers in a way that is the most efficient.
Downstream Bioprocessing
The latter phase of production and development is downstream bioprocessing. Raw materials are extracted or purified during this process. Packaging is also a part of the downstream process. In most cases, labs will begin the downstream process after the earliest product development stage is finished.
Downstream bioprocessing might include the purification of cells that are developed in the upstream process.
The Challenges of Bioprocessing
Time
Bioprocessing can be challenging because of the time factor. Both the upstream and downstream process can take a long time to be finalised.
Cost
Another issue when it comes to bioprocessing is how costly it is. When making new products, companies usually have to adhere to tight budgets. However, it can be difficult to achieve this because of how costly the research, development, and production process can be.
Optimising cell culture media
During upstream bioprocessing, cell culture media can be difficult to optimise. The speed at which labs can grow and nurture organisms can be affected by individual properties of cell culture media formulations.
Isolating cell lines
A challenge that hugely affects the biopharmaceutical industry is identifying and extracting cell lines that are of high value. Much time and money is saved by making the cell isolation process faster.
Bioelectrocatalysis is an integrative area of study that adds biocatalysis and electrocatalysis by using materials made from biological systems as catalysts to stimulate the redox reactions that happen on an electrode.
Applications of Bioprocessing
Being able to separate and extract specific cell lines and parts has been useful to a wide range of industries. Here are some of the ways in which bioprocessing can be applied:
Bioprocessing and Biofuels
Bioprocessing can be used to produce biofuels. Biofuels are obtained from renewable biological resources and they serve as an alternative to fossil fuels. As the demand for eco-friendly energy sources increases, the demand for biofuels also increases. This indicates the significance of biofuels.
Bioprocessing and the Fight Against Antibiotic Resistance
The worsening issue of antibiotic resistance could be resolved by the application of bioprocessing. Many diseases are becoming more and more resistant to antibiotics, as are many people dying as a result of microbial resistance. Bioprocessing can aid in resolving this dilemma. The process helps to create inventive strategies to produce antibiotics. Researchers either have the option to improve existing antibiotics or find novel bioactive compounds from microbial sources.
Exploring the different types of bioprocesses highlights the wide variety of techniques that are crucial to utilising biological systems for various applications. All bioprocesses play vital roles in advancing fields such as medicine, agriculture, and environmental science. Embracing each bioprocess not only enhances scientific innovation but also helps address global challenges. Fermentation tubes, Tools that are of use in bioprocessing are incubators. At Techmate, we have incubators to help your upstream bioprocess. You can either have a look through our catalogue of products or contact us to find the most suitable lab equipment for you.
Bioprocessing is a rapidly growing field with a wide range of applications. The different types of bioprocess modes, including batch culture, fed-batch culture, continuous culture, and perfusion culture, all have their unique advantages and disadvantages. Regardless of the bioprocessing method used, having the right equipment is crucial for achieving optimal results. We offer a wide range of equipment used for bioprocessing, including fermentation tubes, centrifuges, and incubators. Customers can browse our catalogue or contact us directly to speak with our team members who can help them find the right equipment for their bioprocessing needs.
