Bioproduction is a manufacturing process that employs living biological systems to create various products. It involves utilizing whole organisms, cells, or their molecular components to synthesize commercially important biomaterials and molecules.
The Living Systems Used in Bioproduction
Microorganisms serve as versatile biological factories in bioproduction due to their rapid growth and straightforward cultivation. Bacteria such as Escherichia coli (E. coli) are widely used for producing simpler, non-glycosylated proteins, including human insulin and growth hormones. Their well-understood genetics and high yield capabilities make them a frequent choice.
Yeasts like Saccharomyces cerevisiae are another common microbial system, known for their ability to ferment sugars into alcohol and carbon dioxide. This unicellular fungus is utilized in producing biofuels like ethanol and certain therapeutic proteins, including some forms of insulin. Yeasts offer advantages such as fast growth rates, low media costs, and the capacity to secrete proteins, simplifying purification.
Mammalian cells, particularly Chinese Hamster Ovary (CHO) cells, are extensively used for producing complex human proteins. These cells can perform intricate post-translational modifications, such as glycosylation, necessary for the proper function and stability of many therapeutic proteins like monoclonal antibodies. CHO cells are favored because they can be cultured in large suspension systems and are compatible with human protein processing. Over 70% of approved recombinant therapeutic proteins are currently produced using CHO cells. Other biological systems, including plant cells and insect cells, are also explored for specific bioproduction needs.
Fundamental Bioproduction Methods
Bioproduction relies on specialized vessels called bioreactors to cultivate biological systems under controlled conditions. A bioreactor provides a precise environment, regulating parameters such as temperature, pH levels, oxygen supply, and nutrient availability. This controlled setting allows cells or microorganisms to grow and produce the desired substance efficiently and at a large scale. The vessel design, mixing systems, and monitoring capabilities ensure optimal conditions for production.
The overall bioproduction process is divided into two main phases: upstream and downstream processing. Upstream processing encompasses all initial steps involved in cultivating the living cells or microorganisms that will produce the target product. This phase includes preparing the nutrient media, developing the initial cell culture (inoculum), and cultivating the cells within the bioreactor. For instance, in brewing, the fermentation of sugars by yeast represents the upstream phase.
Following cultivation, downstream processing focuses on recovering, purifying, and preparing the product for its intended use. This phase involves separating the cells from the culture broth through methods like centrifugation or filtration. Subsequently, the desired product is isolated from other cellular components and impurities, often requiring multiple purification steps. The final steps include formulation, where stabilizers are added, and packaging. Continuing the brewing analogy, filtering the beer and bottling it would be considered downstream processing.
Common Products of Bioproduction
Bioproduction yields a wide array of products impacting various sectors. Therapeutic proteins represent a major category, including medications that treat diseases. Insulin, for instance, is produced using genetically engineered E. coli or Saccharomyces cerevisiae to manage diabetes, providing a consistent and safe supply that replaced animal-derived sources. Monoclonal antibodies, complex proteins designed to target specific cells or pathogens, are widely used in treating cancers and autoimmune disorders, with CHO cells being the primary production platform. Vaccines, developed to stimulate the immune system against infectious diseases, also involve the cultivation of specific viral or bacterial strains.
Industrial enzymes and chemicals are another significant output of bioproduction. Enzymes are biological catalysts that accelerate specific chemical reactions and are used in numerous industrial processes. For example, proteases and amylases are incorporated into laundry detergents to break down protein and starch stains, enhancing cleaning efficiency. Bioproduction also manufactures chemicals like citric acid, a common additive in food and beverages for flavor and preservation, often produced through the fermentation activity of fungi such as Aspergillus niger.
Biofuels and bioplastics offer more sustainable alternatives to petroleum-based products. Bioethanol, a common biofuel, is produced by fermenting plant sugars from sources like corn or sugarcane using microorganisms such as Saccharomyces cerevisiae. This renewable fuel can be blended with gasoline, reducing reliance on fossil fuels. Bioplastics, derived from renewable biomass sources like corn starch, potato starch, or sugarcane, are designed to be biodegradable or compostable. Examples include polylactic acid (PLA) and polyhydroxyalkanoates (PHA), used to create packaging materials, single-use items, and even cell phone cases.
Applications in Modern Industries
Bioproduction enables the development of treatments in the healthcare sector. It facilitates the creation of personalized medicines, where therapies can be tailored to an individual’s genetic makeup or specific disease characteristics. The ability to produce complex biologics, such as gene therapy vectors and therapeutic proteins, provides novel approaches for conditions previously considered untreatable.
Bioproduction also extends into agriculture and food industries, enhancing efficiency and sustainability. Enzymes produced through bioproduction are used in food processing to improve flavors, extend shelf life, and ensure food safety, as seen in the production of cheese, bread, and yogurt. Biotechnology contributes to developing resilient crops and creating sustainable protein sources, such as cultivated meat, to reduce the environmental footprint of traditional farming.
Bioproduction plays a role in fostering sustainable energy and environmental solutions. The production of biofuels like bioethanol and biodiesel helps to diversify energy sources and reduce greenhouse gas emissions. Bioplastics offer alternatives to conventional plastics, contributing to waste reduction and the development of a circular economy. Bioproduction supports greener manufacturing processes and a reduced reliance on fossil resources.