Our fermentation specialists maximize yield while maintaining the highest quality product. Process optimization is key to reducing potential pitfalls, such as formation of product related impurities or improper folding, leading to insoluble aggregate. Our experience with upstream optimization techniques and materials allows us to produce the most functional protein or plasmid DNA candidate. The choice of expression system and product localization will then drive the primary recovery approach. The upstream development laboratory is equipped to deal with most unit operations.
Scaling-up of traditional Pichia fermentation processes can be challenging due to complex steps and feed regimes. In addition, typical fermentation times require a long guaranteed sterility of the vessel and medium. To address these challenges, we have developed Pichia 2.0, a proprietary expression system and associated upstream process specifically designed for easy implementation in large-scale plants. This system delivers high titers in drastically-reduced fermentation times that approximate E.coli processes.
The advantages of the new Pichia 2.0 system include a shorter screening process in strain development with upstream protocols which are based on easy-to-implement fermentation regimes that deliver high space-time yields (STYs) with shorter product retention time in the supernatant for improved product quality. This system also allows for easier transition into single-use bioreactors, as the Pichia 2.0 process demands much less oxygen and produces significantly less heat compared to AOX1 processes.
Lonza’s fermentation expertise includes:
- Fermentation development
- Miniature bioreactor systems (15mL and 250mL)
- Feed strategy optimization
- Media optimization
- Induction kinetics optimization
- Recovery and separation development
- Inclusion body expression and recovery optimization (E. coli)
- High cell-density fermentation