GENERALIZED VIEW OF BIOPROCESS

RAW MATERIALS
UPSTREAM PROCESSES
Media Formulation
Inoculum
Equipment
and
Preparation
Sterilization
Sterilization
BIOREACTOR - FERMENTER
Reaction Kinetics Transport Phenomena Instrumentation
and Bioactivity
and Fluid Properties
and Control
DOWNSTREAM PROCESSES
Recovery and
Waste Recovery,
Separation
Purification
Reuse and Treatment
THE BOTTOM LINE
REGULATION

ECONOMICS HEALTH AND SAFETY

Bioprocessing is an essential part of many food,

chemical and pharmaceutical industries. Bioprocess
operations make use of microbial, animal and plant
cells and components of cells such as enzymes to
manufacture new products and destroy harmful
wastes.
Use of microorganisms to transform biological
materials for production of fermented foods has its
origins in ancient times. Since then, bioprocesses
have been developed for an enormous range of
commercial products, from relatively cheap materials
such as industrial alcohol and organic solvents, to
expensive specialty chemicals such as antibiotics,
therapeutic proteins and vaccines.
Industrially-useful enzymes and living cells such as
bakers'and
brewers'yeast
are
also
commercialproducts of bioprocessing.

Table 1.1 gives examples of bioprocesses employing whole cells. Typical organisms
used and the approximate market size for the products are also listed. The table is by
no means complete; not included are processes for wastewater treatment,
bioremediation, microbial mineral recovery and manufacture of traditional foods and
beverages such as yoghurt, bread, vinegar, soy sauce, beer and wine. Industrial
processes employing enzymes are also not listed in Table 1.1; these include brewing,
baking,

confectionery

manufacture,

fruit-juice

clarification

and

antibiotic

transformation. Large quantities of enzymes are used commercially to convert starch

into fermentable sugars which serve as starting materials for other bioprocesses.

Our ability to exploit the capabilities of cells and enzymes has been
closely related to advancements in microbiology, biochemistry and
cell physiology. Knowledge in these areas is expanding rapidly; tools
of modern biotechnology such as recombinant DNA, tissue culture
offer new opportunities to develop novel products or improve
bioprocessing methods. Visions of sophisticated medicines, cultured
human tissues and organs, biochips for new-age computers,
environmentally-compatible

pesticides

and

powerful

pollution-

degrading microbes indicate a revolution in the role of biology in

industry.

Typical

New

Product

From

Recombinant

DNA

The interdisciplinary nature of bioprocessing is evident if we look at the stages of

development required for a complete industrial process. As an example, consider
manufacture of a new recombinant-DNA-derived product such as insulin, growth hormone
or interferon. As shown in Figure 1.1, several steps are required to convert the idea of the
product into commercial reality; these stages involve different types of scientific expertise.

The first stages of bioprocess development are concerned

with genetic manipulation of the host organism; in this case,
a gene from animal DNA is cloned into Escherichia coil.
Genetic engineering is done in laboratories on a small scale
by scientists trained in molecular biology and biochemistry.
Tools of the trade include Petri dishes, micropipettes,
microcentrifuges,

nano-or

microgram

quantities

of

restriction enzymes, and electrophoresis gels for DNA and

protein

fractionation.

In terms of bioprocess development, parameter of major importance

is stability of the constructed strains. After cloning the growth and
production characteristics of the cells must be measured as a function
of culture environment. Practical skills in microbiology and kinetic
analysis are required; small-scale culture is mostly carried out using
shake flasks of 250-ml to 1-1itre capacity. Medium composition, pH,
temperature and other environmental conditions allowing optimal
growth and productivity are determined. Calculated parameters such
as cell growth rate, specific productivity and product yield are used to
describe
performance
of
the
organism.

Genetic Engineering

Microbiology
Study of microscopic organisms
Important branch of science
As a basic biological science
Deals with nature of life processes and
principles behind, genetics

As an applied biological science

Study of useful as well as pathogenic
microorganisms

Industrial Microbiology
Study of the exploitation of the
biochemical potential of microbes for
the production of various products
Antibiotics, vaccines, steroids,
solvents, vitamins etc.
Developments of new products using
genetic engineering

Microsopy
Microorganisms are measured in
smaller units such as microns,
nanometers, millimicrons and
Angstrom
Various microscopes
Difference between ordinary and
electron microscope

Range of microscopic
measurements

Why microbiology is
important?
In biochemical engineering
To understand and analyze the process of
biotechnology
Design and operate different units in rational a way
Therefore, a basic knowledge of cell growth and
function is required
A living microorganism may be conceptualized as a
chemical reactor (take nutrients from environment,
grows, reproduces and releases products)
Products formed and released during cellular
activities could be commercially important

Why microbiology is
important?
Rates of nutrient utilization, growth and release
of products depends upon:
Type of the cells involved
Temperature
Composition of media etc.
Quantitative understanding of biological systems
(correlation of friction factor and Reynolds No.)
Understanding above interactions requires a
foundation built on microbiology and
biochemistry

Industrial Microbiology
Study of the exploitation of the
biochemical potential of microbes for
the production of various products
Antibiotics, vaccines, steroids,
solvents, vitamins etc.
Developments of new products using
genetic engineering