The document outlines the essential components and processes of bioprocess technology, emphasizing the distinction between upstream and downstream processes in fermentation. It discusses various types of fermentation based on oxygen presence, operational mode, and nutrient substratum, along with specific methodologies such as batch, continuous, and fed-batch fermentation. Additionally, it highlights the historical development and applications of bioprocess technology in producing primary and secondary metabolites for various industries.

1. Bioprocess technology
MODULE I Introduction to Bioprocesses
Dr. P. Vidya
Prof & Head
P.G & Research Dept
Of Microbiology
D.G Vaishnav college.
Chennai

2. Components of Bioprocess/ fermentation
Technology
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3. Components of Bioprocess/ fermentation Technology
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Upstream processing includes formulation of the fermentation
medium, sterilisation of air, fermentation medium and the fermenter, inoculum
preparation and inoculation of the medium.
The fermentation process involves the propagation of the microorganism and
production of the desired product. The fermentation process can be categorised
depending on various parameters.
It can be either aerobic fermentation, carried out in the presence of oxygen or
anaerobic fermentation, carried out in the absence of oxygen. Many industrial
fermentation are carried out under aerobic conditions where a few processes such
as ethanol production by yeast require strictly anaerobic environments.
Downstream Processing includes the recovery of the products in a pure state
and the effluent treatment. Product recovery is carried out through a series of
operations including cell separation by settling, centrifugation or filtration;
product recovery by disruption of cells (if the product is produced intracellularly);
extraction and purification of the product. Finally, the effluents are treated by
chemical, physical or biological methods.

5. The stages in BioprocessTechnology
1
• Screening of Organisms
2
• Substrates and media
3
• Frementers design &
• Fermentation
Upstream
processing
Fermentation

6. The stages in BioprocessTechnology
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• Harvesting
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• purification and final product
• processing.
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• Qc & Despatching
Downstream
Processing

7. A. Upstream processes
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10. B. Production process
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Continuous monitoring the production process to
maintain best possible conditions for maximum
product formation
Following are the certain essential operations which needs
continuous monitoring.
❑ Change in pH of the medium and its control
❑ Fluctuation in temperature inside the fermenter and its
control through cooling system
❑ Production of foam and breaking it by adding
antifoam agents
❑ Supply of sterile oxygen in case of aerobic condition

11. C. Downstream processes
Down Stream processing” – a collective term for all the steps which
required in order actually recover useful products from any kind of
industrial process.
Following are the steps of downstream process
• The extraction of the product and its purification
• The disposal of effluents produced by the process.

12. Downstream processes
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intracellular literally
means 'within the
cell,
Extracellular
definition is -
situated or
occurring outside a
cell

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Types of Fermentation
I.Based on presence or absence of oxygen
II. Based on mode of operation
III. Based on nutrient substratum

15. I.Based on presence or absence of
oxygen
Aerobic
Fermentation
Anaerobic
Fermentation

16. Aerobic Fermentation
• “Aerobic” means “in the presence of oxygen”
Some types of fermentation processes require oxygen
Oxygen is required for the reproduction and growth of microorganisms
(Yeast/Bacteria etc)
The main feature of aerobic fermentation is the provision for adequate aeration.
In addition, these fermenters may have a mechanism for stirring and mixing of the
medium and cells.

17. Applications
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In most of the commercial processes and majority of the products
of human utility are produced by this type of fermentation.
Antibiotics
pickles, sauerkraut, soy sauce
vitamins,
pharmaceuticals

18. Anaerobic Fermentation
Anaerobic fermentation is a method cells use to
extract energy from carbohydrates when oxygen or
other electron acceptors are not available in the
surrounding environment
In anaerobic fermentation, a provision for aeration is
usually not needed.
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20. Alcoholic fermentation in yeast
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22. II. Based on mode of opreation
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1.Batch Fermentation
2. Continuous Fermentation
3. Fed Batch Fermentation

23. 1. Batch Fermentation:
• A batch fermentation is a closed culture system, because initial and
limited amount of sterilized nutrient medium is introduced into the
fermenter.
• The medium is inoculated with a suitable microorganism and incubated
for a definite period for fermentation to proceed under optimal
physiological conditions.
• Oxygen in the form of air, an antifoam agent and acid or base, to control
the pH, are being added during the course of fermentation process.
• Batch fermentation may be used to produce biomass, primary metabolites
and secondary metabolites

24. 2. Continuous Fermentation:
It is a closed system of fermentation, run for indefinite
period.
In this method, fresh nutrient medium is added
continuously or intermittently to the fermenter and
equivalent amount of used medium with
microorganisms is withdrawn continuously or
intermittently for the recovery of cells or fermentation
products

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A continuous fermentation is generally carried out in
the following ways:
(a) Single stage fermentation
(b) Recycle fermentation
(c) Multiple stage fermentation

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The process of continuous fermentation is monitored either by
microbial growth activity or by product formation and these
methods are called:
(i) Turbidostat method, and
(ii) Chemostat method.

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3.Fed Batch Fermentation:
• It is a modification to the batch fermentation.
• In this process substrate is added periodically in instalments as
the fermentation progresses, due to which the substratum is
always at an optimal concentration.
• This is essential as some secondary metabolites are subjected
to catabolite repression by high concentration of either glucose,
or other carbohydrate or nitrogen compounds present in the
medium.
• This method is generally employed for the production of

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III. Based on nutrient substratum
Surface
fermentations
Submerged
fermentation
Solid State / Substrate
Fermentation (SSF)

29. Surface fermentations
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• Surface fermentations are those
where the substratum may be solid
or liquid.
• The organism grows on the
substratum and draws the nutrients
from the substratum.
• These techniques are very
complicated and rarely used in
industry

30. Submerged fermentation
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• In the submerged process, the substrate used for fermentation is always
in liquid state which contains the nutrients needed for growth.
• The fermentor which contains the substrate is operated continuously and
the product biomass is continuously harvested from the fermenter by
using different techniques then the product is filtered or centrifuged and
then dried.
• Submerged fermentation is a method of manufacturing biomolecules in
which enzymes and other reactive compounds are submerged in a liquid
such as alcohol, oil or a nutrient broth.

31. Submerged fermentation
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33. Solid State / Substrate Fermentation (SSF)
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• SSF is defined as a fermentation process in which micro-
organisms grow on solid materials in the absence of free
liquid .
• SSF is mostly used for food processing and production of
enzymes using filamentous microorganism like fungi.
• In SSF technique, microorganisms are grown on and inside
the humidified solid substrate.
• Overall efficiency of the SSF basically depends on three ‘E’
factors i.e. Energy, Economy and Environment.

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36. Diffrencess between ssf & smf
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Bioprocess technology
A bioprocess is a specific process
that uses complete living cells or
their components (e.g., bacteria,
enzymes, chloroplasts) to obtain
desired products
agriculture, food, feed,
pharmaceuticals, nutraceuticals,
chemicals, and polymers and
paper from biological materials &
treatment of waste water
HISTORY
Fermented foods such as yoghurt,
cheese, soya sauce, pickled
cabbage-
Beer-recovered from the pyramids
gun powder- In Renaissance
The Aztecs of Mexico cultured
Spirulina
Soma juice prepared by the Vedic
Aryan
French wine and French cheeses
Penicillin
ethanol and solvents such as
acetone and butanol by
fermentation
Microbiologists consider
fermentation as 'any
process for the
production of a product
by means of mass culture
of micro-organisms
Biochemists consider
fermentation as 'an
energy-generating
process in which organic
compounds act both as
electron donors and
acceptors

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Traditional fermentation
using living organisms to
yield new products
• spontaneous uncontrolled
• cheese/yoghurt, bread,
beer and wine
Modern fermentation
using genetically modified
organisms to yield new products
Cultivation in controlled
conditions
Recombinant DNA techniques &
Biochemical engineering
Food & Beverages
Biopharmaceutical
Energy
Primary metabolites are made during normal growth
• Essential for proper growth, development, and
reproduction
• produced during the log phase (trophophase) of the growth
• proteins, enzymes, nucleic acids, ethanol, lactate etc.
Secondary metabolites are produced during stationary
phase(“idiophase).
• The products of secondary metabolism are not absolutely
required for the survival of the organisms
• Toxins, gibberellins, alkaloids, antibiotics, and biopolymers
are examples of secondary metabolites.
• Not all microbes produce secondary metabolites

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Types of Fermentation
I.Based on presence or absence of oxygen -
Aerobic & anerobic
II. Based on mode of operation - Batch,
FedBatch, and Continuous Fermentation
III. Based on nutrient substratum - surface
submerged and solid state fermentation
Basic steps
• Screeinng
• Media formulation
• Sterilization of the medium &
fermenters
• Inoculation in production vessel
• Growth of the organism under
optimum conditions for product
formation
• Extraction and purification of the
product
• Effluent disposal produced by the
process

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MODULE I
Historical development of bioprocess technology
Traditional and modern applications of fermentation technology
Range of fermentation processes
Primary and secondary metabolites
Components of fermentation process
Approaches to metabolic engineering

43. Any questions?
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The benefits of biotechnology could not be
realized
without bioprocess technology