Predicting the amorphous-phase composition during lyophilization.

The glass-transition temperature and the composition of the amorphous phase/maximally concentrated solution (classically referred to as Tg' and wg', respectively) as function of added excipients are crucial for the design of lyophilization processes. Whereas the determination of Tg' can be accomplished easily using mDSC, the determination of wg' poses challenges, since the experimental effort needs to be redone for each new excipient mixture (limited transferability of the results possible). In this work, an approach was developed which allows to predict wg' for (1) single excipients, (2) given compositions of a binary excipient mixture, and (3) single excipients in aqueous (model) protein solutions using the thermodynamic model PC-SAFT and one experimental data point of Tg'. Sucrose, trehalose, fructose, sorbitol, and lactose were considered as single excipients. The binary excipient mixture consisted of sucrose and ectoine. The model protein was bovine serum albumin in combination with sucrose. The results reveal that the new approach can precisely predict wg' in the systems considered, including the non-linear course of wg' identified for different sucrose/ectoine ratios. The same applies to the course of wg' as function of the protein concentration. This newly developed approach allows for the reduction of the experimental effort to a minimum.

Continuous phase separation of stable emulsions from biphasic whole-cell biocatalysis by catastrophic phase inversion.

The main bottleneck for the industrial implementation of highly promising multi-phase whole-cell biocatalytic processes is the formation of stable Pickering-type emulsions, hindering efficient downstream processing. Especially for the crucial step of phase separation, state-of-the-art processes require time-consuming and costly process steps (excessive centrifugation/use of de-emulsifiers). In contrast, using the phenomenon of catastrophic phase inversion (CPI), efficient phase separation can be achieved by addition of an excess dispersed phase within minutes. To show applicability of CPI as an innovative process step, a fully automated lab-scale prototype was designed and constructed within this work. A simple mixer-settler set-up enabled a continuous phase separation using CPI termed applied catastrophic phase inversion (ACPI). Test runs were conducted using emulsions from biphasic whole-cell biocatalysis (Escherichia coli JM101 and Pseudomonas putida KT2440 cells). Solvents used included n-heptane, ethyl oleate or 1-octanol as organic phase. These investigations revealed ideal process settings for a stable ACPI process (e.g., flow/stirring rates and volumetric phase ratios between organic and water phase). The knowledge of the CPI point is most crucial, as only the inverted state of emulsion is successfully destabilized.

Influence of Hydrophobic and Hydrophilic Chain Length of CiEj Surfactants on the Solubilization of Active Pharmaceutical Ingredients.

Up to 90% of all newly developed active pharmaceutical ingredients (APIs) are poorly water soluble, most likely also showing a low oral bioavailability. In order to increase the aqueous solubility of these APIs, surfactants are promising excipients to increase both solubility and consequently bioavailability (e.g., in lipid- and surfactant-based drug delivery systems). In this work, we investigated the influence of hydrophobic and hydrophilic chain lengths of CiEj surfactants (C8E6, C10E6, and C10E8) toward the solubilization of fenofibrate, naproxen, and lidocaine. Furthermore, we investigated the partitioning of these APIs between the surfactant aggregates and the surrounding aqueous bulk phase. For all APIs considered, we determined the locus of API solubilization as well as the individual aggregation numbers (Nagg) of surfactants and API molecules in an API/surfactant aggregate. We further determined the hydrodynamic radius (Rh) of the API/surfactant aggregates in the absence and presence of the APIs. The size of the API/surfactant aggregates (Nagg, Rh) passes through a minimum upon lidocaine solubilization; it gradually increases upon naproxen solubilization and is almost constant upon fenofibrate solubilization. The results give valuable insights into the solubilization mechanisms of APIs in the CiEj surfactant aggregates. Our results reveal that fenofibrate is solely solubilized in the hydrophobic core of the CiEj surfactant aggregates, as only the hydrophobic chain length of the surfactant influences its solubilization. Naproxen is solubilized in the palisade layer of the surfactant aggregates, as both the hydrophobic and hydrophilic chain lengths are decisive for its solubilization. Lidocaine is mainly solubilized in the rather hydrophilic corona region of the surfactant aggregates, as the hydrophilic chain length of the surfactant governs its solubilization. The results further reveal that the hydrophilic/lipophilic balance is not an appropriate measure to estimate the solubilization capacity of surfactant aggregates.

Solubilization of Aldehydes and Amines in Aqueous CiEj Surfactant Aggregates: Solubilization Capacity and Aggregate Properties.

Hydroformylation of olefins to aldehydes and subsequent reductive amination of aldehydes to amines takes place in an aqueous system using a water-soluble catalyst. It is limited to short-chain molecules due to an insufficient solubility of long-chain molecules in water. A promising approach to increase the solubility of long-chain aldehydes and amines is the addition of surfactants to the aqueous phase. In this work, we thus determined the solubilization capacity (SC) of different nonionic CiEj surfactants (C8E6, C10E6, and C10E8) toward long-chain aldehydes and amines. We used static and dynamic light scattering techniques to investigate the influence of both the surfactant and solute molecular structures on the SC as well as on the aggregation number (Nagg) and hydrodynamic radius (Rh) of mixed aggregates. Our data reveals that an optimum ratio of hydrophobic to hydrophilic chain length of CiEj surfactants exists where the SC toward long-chain aldehydes and amines possesses a maximum. Further, the size of the aggregates (Nagg, Rh) passes through a minimum upon amine solubilization, while upon aldehyde solubilization, the aggregate size increases gradually. The results shown in this work give valuable insights to the solubilization of aldehydes and n-amines into nonionic CiEj surfactants and facilitate the search of suitable surfactants for hydroformylation and reductive amination as "green" solvents based on the detailed knowledge about the aggregate structure.

Hydroxylpropyl-ß-cyclodextrin as Potential Excipient to Prevent Stress-Induced Aggregation in Liquid Protein Formulations.

Due to the growing demand for patient-friendly subcutaneous dosage forms, the ability to increasing protein solubility and stability in formulations to deliver on the required high protein concentrations is crucial. A common approach to ensure protein solubility and stability in high concentration protein formulations is the addition of excipients such as sugars, amino acids, surfactants, approved by the Food and Drug Administration. In a best-case scenario, these excipients fulfil multiple demands simultaneously, such as increasing long-term stability of the formulation, reducing protein adsorption on surfaces/interfaces, and stabilizing the protein against thermal or mechanical stress. 2-Hydroxylpropyl-ß-cyclodextrin (derivative of ß-cyclodextrin) holds this potential, but has not yet been sufficiently investigated for use in protein formulations. Within this work, we have systematically investigated the relevant molecular interactions to identify the potential of Kleptose®HPB (2-hydroxylpropyl-ß-cyclodextrin from Roquette Freres, Lestrem, France) as "multirole" excipient within liquid protein formulations. Based on our results three factors determine the influence of Kleptose®HPB on protein formulation stability: (1) concentration of Kleptose®HPB, (2) protein type and protein concentration, and (3) quality of the protein formulation. Our results not only contribute to the understanding of the relevant interactions but also enable the target-oriented use of Kleptose®HPB within formulation design.

Simplified choice of suitable excipients within biologics formulation design using protein-protein interaction- and water activity-maps.

Still today, high-concentration protein formulations are often developed based on high-throughput experimental screening approaches. Although likely delivering working formulations, these approaches do not lead to a deep/mechanistic understanding of the protein phase behavior in solution. Within this work, we thus optimized and enhanced a recent approach for an initial low effort selection of potential excipients and excipient mixtures to be used in high-concentration protein formulations. This approach considers both: molecular interactions and thermodynamic determinants to access the phase behavior of the proteins in solution, as well as pharmaceutical engineering boundaries (such as osmotic pressure and osmolality) to deliver on optimal formulation conditions. Water activity coefficient γW-calculations (used to describe the protein environment in solution), unfolding temperature (conformational stability) and protein-protein interactions (colloidal stability) are used as determinants. Amino acids (20 proteinogenic amino acids), selected amino acid mixtures, as well as mixtures of amino acids and trehalose (l-arginine-trehalose; l-histidine-trehalose) are considered as model excipients. The approach is extends by studying the long-term stability of the predicted formulation conditions for a γ-globulin from human blood and denosumab. The results reveal, that by combining protein-specific experiments as well as model-based studies for the selection of excipient mixtures in high concentration protein formulations, the effort as well as the resource requirements can be reduced significantly.

Influence of Temperature and Concentration on the Self-Assembly of Nonionic CiEj Surfactants: A Light Scattering Study.

Nonionic poly(ethylene oxide) alkyl ether (CiEj) surfactants self-assemble into aggregates of various sizes and shapes above their critical micelle concentration (CMC). Knowledge on solution attributes such as CMC as well as aggregate characteristics is crucial to choose the appropriate surfactant for a given application, e.g., as a micellar solvent system. In this work, we used static and dynamic light scattering to measure the CMC, aggregation number (N agg), and hydrodynamic radius (R h) of four different CiEj surfactants (C8E5, C8E6, C10E6, and C10E8). We examined the influence of temperature, concentration, and molecular structure on the self-assembly in the vicinity of the CMC. A minimum in the CMC vs temperature curve was identified for all surfactants investigated. Further, extending the hydrophilic and hydrophobic chain lengths leads to an increase and decrease of the CMC, respectively. The size of the aggregates strongly depends on temperature. N agg and R h increase with increasing temperature for all surfactants investigated. Additionally, N agg and R h both increase with increasing surfactant concentration. The data obtained in this work further improve the understanding of the influence of temperature and molecular structure on the self-assembly of CiEj surfactants and will further foster their use in micellar solvent systems.

Adaptive laboratory evolution accelerated glutarate production by Corynebacterium glutamicum.

BACKGROUND: The demand for biobased polymers is increasing steadily worldwide. Microbial hosts for production of their monomeric precursors such as glutarate are developed. To meet the market demand, production hosts have to be improved constantly with respect to product titers and yields, but also shortening bioprocess duration is important. RESULTS: In this study, adaptive laboratory evolution was used to improve a C. glutamicum strain engineered for production of the C5-dicarboxylic acid glutarate by flux enforcement. Deletion of the L-glutamic acid dehydrogenase gene gdh coupled growth to glutarate production since two transaminases in the glutarate pathway are crucial for nitrogen assimilation. The hypothesis that strains selected for faster glutarate-coupled growth by adaptive laboratory evolution show improved glutarate production was tested. A serial dilution growth experiment allowed isolating faster growing mutants with growth rates increasing from 0.10 h-1 by the parental strain to 0.17 h-1 by the fastest mutant. Indeed, the fastest growing mutant produced glutarate with a twofold higher volumetric productivity of 0.18 g L-1 h-1 than the parental strain. Genome sequencing of the evolved strain revealed candidate mutations for improved production. Reverse genetic engineering revealed that an amino acid exchange in the large subunit of L-glutamic acid-2-oxoglutarate aminotransferase was causal for accelerated glutarate production and its beneficial effect was dependent on flux enforcement due to deletion of gdh. Performance of the evolved mutant was stable at the 2 L bioreactor-scale operated in batch and fed-batch mode in a mineral salts medium and reached a titer of 22.7 g L-1, a yield of 0.23 g g-1 and a volumetric productivity of 0.35 g L-1 h-1. Reactive extraction of glutarate directly from the fermentation broth was optimized leading to yields of 58% and 99% in the reactive extraction and reactive re-extraction step, respectively. The fermentation medium was adapted according to the downstream processing results. CONCLUSION: Flux enforcement to couple growth to operation of a product biosynthesis pathway provides a basis to select strains growing and producing faster by adaptive laboratory evolution. After identifying candidate mutations by genome sequencing causal mutations can be identified by reverse genetics. As exemplified here for glutarate production by C. glutamicum, this approach allowed deducing rational metabolic engineering strategies.

Protein-protein interactions and water activity coefficients can be used to aid a first excipient choice in protein formulations.

With respect to all biopharmaceuticals marketed to date, monoclonal antibodies represent the largest fraction with more than 48% market share (2012). However, the development of biopharmaceutical formulations is a challenging task, and time-consuming and cost-intensive high-throughput screenings are still state-of-the-art in formulation design. These screening techniques are almost exclusively based on heuristic decisions thus the benefit in terms of mechanistic understanding is often unclear. It requires novel, physical-sound methods to enhance/optimize future formulation development, ideally by understanding molecular interactions in these complex solutions. A suitable and evaluated measure-of-choice to characterize protein-protein interactions in aqueous protein solutions is the second osmotic virial coefficient B22 which can be measured using static light scattering techniques. Furthermore B22 can be modeled/predicted via the extended mxDLVO model for protein-protein interactions in the presence of single excipients and excipient-mixtures. Building up on this approach, giving an additional insight into water-water and water-excipient interactions, the thermodynamic equation-of-state ePC-SAFT is used to calculate water activity coefficients in the presence of excipient-mixtures. Immunoglobulin G (IgG) was chosen as a model protein to predict B22-values for IgG in the presence of model excipient-mixtures (trehalose-NaCl, l-histidine-trehalose, l-histidine-NaCl). The combination of water activity coefficients and B22 allows to quickly identify a first guess on suitable formulation conditions that then can be further evaluated with existing methods/knowledge.

Selecting Excipients Forming Therapeutic Deep Eutectic Systems-A Mechanistic Approach.

The majority of all newly identified active pharmaceutical ingredients (APIs) have a low solubility in water (partly smaller than marble). In order to enhance their solubility and bioavailability, the formulation of these APIs, as part of therapeutic deep eutectic systems (THEDES), has been recently shown to be a promising approach. By choosing the right excipient, the melting point of the API/excipient mixture can be lowered below body temperature or even room temperature, resulting in a liquid formulation. To date, because of a lack of mechanistic understanding of how THEDES are formed, the identification of suitable excipients for a given API is almost exclusively based on heuristic decisions and trial-and-error-based approaches. This is both very time-consuming and expensive. The purpose of this work is to reduce the experimental effort to identify suitable excipients for a given API solely based on the melting properties (melting temperature and melting enthalpy) of the API and excipient and accounting for intermolecular interactions via a predictive thermodynamic model [in this case, UNIFAC(Do)]. Lidocaine, ibuprofen, and phenylacetic acid were considered as model APIs, whereas thymol, vanillin, lauric acid, para-toluic acid, benzoic acid, and cinnamic acid were considered as model excipients. The formation of THEDES from these components was predicted and confirmed using differential scanning calorimetry. The results indicate that the experimental effort for the identification of suitable API/excipient combinations can be drastically reduced by thermodynamic modeling, leading to more efficient and tailor-made formulations in the future.

Integrated process development of a reactive extraction concept for itaconic acid and application to a real fermentation broth.

Itaconic acid (IA) has a high potential to be used as a bio-based platform chemical and its biocatalytic production via fermentation has significantly improved within the last decade. Additionally downstream processing using reactive extraction (RE) was described, potentially enabling a more efficient sustainable bioprocess producing IA. The bottleneck to overcome is the connection of up- and downstream processing, caused by lack of biocompatibility of the RE systems and direct application to fermentation broth. Within this study, a biocompatible RE system for IA is defined (pH dependency, extraction mechanism) and used for direct application to a fermentation broth. By optimizing the biocatalyst, the production medium, and the extraction system in an integrated approach, it was possible to define critical parameters that enabled a tuning of the overall bioprocess. With an extraction yield of Y IA = 0.80 ± 0.03, IA could be produced as sole carboxylic acid ( b IA , 0 aq  = 0.490 mol/kgaq) using a RE system consisting of ethyl oleate as organic solvent and tri-n-octylamine as extractant ( b T - C 8 org  = 0.6 mol/kgorg). This work is a proof of concept and demonstrates that by joint consideration of up- and downstream processing, optimized bioprocesses can be developed.

Solubilization of proteins in aqueous two-phase extraction through combinations of phase-formers and displacement agents.

The aqueous two-phase extraction (ATPE) of therapeutic proteins is a promising separation alternative to cost-intensive chromatography, still being the workhorse of nowadays downstream processing. As shown in many publications, using NaCl as displacement agent in salt-polymer ATPE allows for a selective purification of the target protein immunoglobulin G (IgG) from human serum albumin (HSA, represents the impurity). However a high yield of the target protein is only achievable as long as the protein is stabilized in solution and not precipitated. In this work the combined influence of NaCl and polyethylene glycol (Mw=2000g/mol) on the IgG-IgG interactions was determined using composition gradient multi-angle light scattering (CG-MALS) demonstrating that NaCl induces a solubilization of IgG in polyethylene glycol 2000 solution. Moreover it is shown that the displacement agent NaCl has a significant and beneficial influence on the IgG solubility in polyethyleneglycol2000-citrate aqueous two-phase system (ATPS) which can also be accessed by these advanced B22 measurements. By simultaneous consideration of IgG solubility data with results of the ATPS phase behavior (especially volume fraction of the respective phases) allows for the selection of process tailored ATPS including identification of the maximum protein feed concentration. Through this approach an ATPS optimization is accessible providing high yields and selectivity of the target protein (IgG).

Applied catastrophic phase inversion: a continuous non-centrifugal phase separation step in biphasic whole-cell biocatalysis.

Biphasic whole-cell biotransformations are known to be efficient alternatives to common chemical synthesis routes, especially for the production of, e.g. apolar enantiopure organic compounds. They provide high stereoselectivity combined with high product concentrations owing to the presence of an organic phase serving as substrate reservoir and product sink. Industrial implementation suffers from the formation of stable Pickering emulsions caused by the presence of cells. State-of-the-art downstream processing includes inefficient strategies such as excessive centrifugation, use of de-emulsifiers or thermal stress. In contrast, using the catastrophic phase inversion (CPI) phenomenon (sudden switch of emulsion type caused by addition of dispersed phase), Pickering-type emulsions can be destabilized efficiently. Within this work a model system using bis(2-ethylhexyl) phthalate (BEHP) as organic phase in combination with E. coli, JM101 was successfully separated using a continuous mixer settler setup. Compared to the state-of-the-art centrifugal separations, this process allows complete phase separation with no detectable water content or cells in the organic phase with no utilities/additives required. Furthermore, the concentration of the product is not affected by the separation. It is therefore a simple applicable method that can be used for separation of stable Pickering-type emulsions based on the knowledge of the point of inversion.

Novel Displacement Agents for Aqueous 2-Phase Extraction Can Be Estimated Based on Hybrid Shortcut Calculations.

The purification of therapeutic proteins is a challenging task with immediate need for optimization. Besides other techniques, aqueous 2-phase extraction (ATPE) of proteins has been shown to be a promising alternative to cost-intensive state-of-the-art chromatographic protein purification. Most likely, to enable a selective extraction, protein partitioning has to be influenced using a displacement agent to isolate the target protein from the impurities. In this work, a new displacement agent (lithium bromide [LiBr]) allowing for the selective separation of the target protein IgG from human serum albumin (represents the impurity) within a citrate-polyethylene glycol (PEG) ATPS is presented. In order to characterize the displacement suitability of LiBr on IgG, the mutual influence of LiBr and the phase formers on the aqueous 2-phase system (ATPS) and partitioning is investigated. Using osmotic virial coefficients (B22 and B23) accessible by composition gradient multiangle light-scattering measurements, the precipitating effect of LiBr on both proteins and an estimation of both protein partition coefficients is estimated. The stabilizing effect of LiBr on both proteins was estimated based on B22 and experimentally validated within the citrate-PEG ATPS. Our approach contributes to an efficient implementation of ATPE within the downstream processing development of therapeutic proteins.

Protein partition coefficients can be estimated efficiently by hybrid shortcut calculations.

The extraction of therapeutic proteins like monoclonal antibodies in aqueous two-phase systems (ATPS) is a suitable alternative to common cost intensive chromatographic purification steps within the downstream processing. Thereby the protein partitioning can be selectively changed using a displacement agent (additional salt) in order to allow for a successful purification of the target protein. Within this work a new shortcut strategy for the calculation of protein partition coefficients in polymer-salt ATPS is presented. The required protein-solute (phase-forming component, displacement agent) interactions are covered by the cross virial coefficient B23 measured by composition gradient multi-angle light scattering (CG-MALS). Using this shortcut calculation allows for an efficient determination of the partition coefficients of the target protein immunoglobulin G (IgG) and the impurity human serum albumin (HSA) within PEG-citrate and PEG-phosphate ATPS independently on the protein concentration. We demonstrate that the selection of a suitable displacement agent allowing for a selective purification of IgG from HSA is accessible by B23. Based on the determination of the protein-protein interactions via CG-MALS covered by the second osmotic virial coefficient B22 a further optimization of ATPS preventing protein precipitation is enabled. The results show that our approach contributes to an efficient downstream processing development.

Inclusion of mPRISM potential for polymer-induced protein interactions enables modeling of second osmotic virial coefficients in aqueous polymer-salt solutions.

The downstream processing of therapeutic proteins is a challenging task. Key information needed to estimate applicable workup strategies (e.g. crystallization) are the interactions of the proteins with other components in solution. This information can be deduced from the second osmotic virial coefficient B22 , measurable by static light scattering. Thermodynamic models are very valuable for predicting B22 data for different process conditions and thus decrease the experimental effort. Available B22 models consider aqueous salt solutions but fail for the prediction of B22 if an additional polymer is present in solution. This is due to the fact that depending on the polymer concentration protein-protein interactions are not rectified as assumed within these models. In this work, we developed an extension of the xDLVO model to predict B22 data of proteins in aqueous polymer-salt solutions. To show the broad applicability of the model, lysozyme, γ-globulin and D-xylose ketol isomerase in aqueous salt solution containing polyethylene glycol were considered. For all proteins considered, the modified xDLVO model was able to predict the experimentally observed non-monotonical course in B22 data with high accuracy. When used in an early stage in process development, the model will contribute to an efficient and cost effective downstream processing development.

Non-monotonic course of protein solubility in aqueous polymer-salt solutions can be modeled using the sol-mxDLVO model.

Protein purification is often performed using cost-intensive chromatographic steps. To discover economic alternatives (e.g., crystallization), knowledge on protein solubility as a function of temperature, pH, and additives in solution as well as their concentration is required. State-of-the-art models for predicting protein solubility almost exclusively consider aqueous salt systems, whereas "salting-in" and "salting-out" effects induced by the presence of an additional polymer are not considered. Thus, we developed the sol-mxDLVO model. Using this newly developed model, protein solubility in the presence of one salt and one polymer, especially the non-monotonic course of protein solubility, could be predicted. Systems considered included salts (NaCl, Na-p-Ts, (NH(4))(2) SO(4)) and the polymer polyethylene glycol (MW: 2000 g/mol, 12000 g/mol) and proteins lysozyme from chicken egg white (pH 4 to 5.5) and D-xylose ketol-isomerase (pH 7) at 298.15 K. The results show that by using the sol-mxDLVO model, protein solubility in polymer-salt solutions can be modeled in good agreement with the experimental data for both proteins considered. The sol-mxDLVO model can describe the non-monotonic course of protein solubility as a function of polymer concentration and salt concentration, previously not covered by state-of-the-art models.

Osmotic Virial Coefficients as Access to the Protein Partitioning in Aqueous Two-Phase Systems.

A promising alternative to state of the art chromatographic separations of therapeutic proteins is the extraction of the target protein using an aqueous two-phase system (ATPS). The use of an additional salt working as a displacement agent can influence the protein partitioning behavior in ATPS and thus enable a selective purification of the target protein. The selection of a suitable ATPS for protein extraction requires information concerning the protein-protein interactions (second osmotic virial coefficient B22 ) as well as the interactions between protein and solute (displacement agent and phase-forming components) (cross virial coefficient B23 ). In this work, the partitioning behavior and the precipitation affinity of immunoglobulin G (IgG) is considered within a polyethylene glycol (PEG)-phosphate ATPS. The influence on IgG partitioning upon addition of NaCl and (NH4)2 SO4 was investigated. In order to access the IgG precipitation affinity and the IgG partitioning behavior, the B22 and B23 values were determined for several combinations of solute [PEG, phosphate buffer, NaCl, and (NH4)2 SO4 ] and IgG based on static light scattering measurements. A qualitative estimation of the IgG precipitation affinity and the suitability of a solute as potential displacement agent within the PEG-phosphate ATPS on the basis of the measured B22 and B23 values is presented.

Process boundaries of irreversible scCO2 -assisted phase separation in biphasic whole-cell biocatalysis.

The formation of stable emulsions in biphasic biotransformations catalyzed by microbial cells turned out to be a major hurdle for industrial implementation. Recently, a cost-effective and efficient downstream processing approach, using supercritical carbon dioxide (scCO2 ) for both irreversible emulsion destabilization (enabling complete phase separation within minutes of emulsion treatment) and product purification via extraction has been proposed by Brandenbusch et al. (2010). One of the key factors for a further development and scale-up of the approach is the understanding of the mechanism underlying scCO2 -assisted phase separation. A systematic approach was applied within this work to investigate the various factors influencing phase separation during scCO2 treatment (that is pressure, exposure of the cells to CO2 , and changes of cell surface properties). It was shown that cell toxification and cell disrupture are not responsible for emulsion destabilization. Proteins from the aqueous phase partially adsorb to cells present at the aqueous-organic interface, causing hydrophobic cell surface characteristics, and thus contribute to emulsion stabilization. By investigating the change in cell-surface hydrophobicity of these cells during CO2 treatment, it was found that a combination of catastrophic phase inversion and desorption of proteins from the cell surface is responsible for irreversible scCO2 mediated phase separation. These findings are essential for the definition of process windows for scCO2 -assisted phase separation in biphasic whole-cell biocatalysis.

The dynamic influence of cells on the formation of stable emulsions in organic-aqueous biotransformations.

Emulsion stability plays a crucial role for mass transfer and downstream processing in organic-aqueous bioprocesses based on whole microbial cells. In this study, emulsion stability dynamics and the factors determining them during two-liquid phase biotransformation were investigated for stereoselective styrene epoxidation catalyzed by recombinant Escherichia coli. Upon organic phase addition, emulsion stability rapidly increased correlating with a loss of solubilized protein from the aqueous cultivation broth and the emergence of a hydrophobic cell fraction associated with the organic-aqueous interface. A novel phase inversion-based method was developed to isolate and analyze cellular material from the interface. In cell-free experiments, a similar loss of aqueous protein did not correlate with high emulsion stability, indicating that the observed particle-based emulsions arise from a convergence of factors related to cell density, protein adsorption, and bioreactor conditions. During styrene epoxidation, emulsion destabilization occurred correlating with product-induced cell toxification. For biphasic whole-cell biotransformations, this study indicates that control of aqueous protein concentrations and selective toxification of cells enables emulsion destabilization and emphasizes that biological factors and related dynamics must be considered in the design and modeling of respective upstream and especially downstream processes.