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A novel continuous two-phase dispersion process was developed to produce κ-carrageenan gel microspheres, using static mixers. It was shown that yeast-loaded carrageenan beads, with controlled diameter and tight size distribution, can be produced on a continuous basis, in a scalable mixer, at production rates appropriate to both pilot plant-scale and, potentially, industrial-scale operations. Immobilized yeast are intended to be used in continuous brewing operations. The effects of the static mixer diameter (D), the number of mixing elements (N e ), the fluid linear velocity (V), and the volumetric fraction (e) of κ-carrageenan, on the mean diameter and size distribution of the resulting gel microspheres, were studied. Image analysis showed that mean diameter was strongly influenced by the average linear fluid velocity through the mixer, and by the mixer diameter. The number of mixer elements and the mixer diameter governed bead size dispersion. A productivity of 10 L h -1 of beads was attained using a 1.27-cm-diameter static miter. Because the productivity is proportional to the mixer diameter squared, this process, although suited for the production of small-size beads (down to 50 μm), would be technically and economically feasible for a large industrial immobilization process. However, because the coefficient of variability increased with mixer diameter, and thus with scale-up, operational improvements are suggested, such as the use of smaller-diameter mixers operating in parallel, to reduce the size dispersion.

Smooth and spherical alginate microspheres and nylon-membrane bound microcapsules were formed in an air-agitated, liquid-liquid mixer by emulsification/internal gelation and interfacial polymerization respectively. The mean diameter of the alginate microspheres ranged from 100 to 800 microm, and was controlled by process modifications. Increase in emulsifier concentration, gas flowrate, and emulsification time resulted in smaller microsphere size as did a decrease in liquid height. Increase in the dispersed phase viscosity resulted in a longer emulsification time required for approaching a minimum microsphere size. Microspheres could be formed with the proportion of dispersed phase approaching 30%. The yield of alginate microspheres was 70%, with losses attributed to incomplete recovery during washing and filtration operations. The yield of DNA encapsulation within the fraction of recovered microspheres, was 94%. The small loss was thought to occur by surface release during the washing of the microspheres. (c) 1997 John Wiley & Sons, Inc. Biotechnol Bioeng 56: 464-470, 1997.

Co-guanidine membranes were shown to form intact, ionically complexed membranes on alginate beads, serving as an alternative to the commonly used polymers, poly-L-lysine and chitosan. DNA was encapsulated and membrane thickness, the level of DNA protection from nuclease diffusion and the degree of DNA-complexation with co-guanidine membranes were all shown to be dependent on both polymer concentration and coating time. The highest level of DNAse exclusion was possible within beads coated with a polymer concentration of 5 mg/ml. Recovery of double-stranded DNA after nuclease exposure for 60 min reached 90% of that initially encapsulated. The molecular weight cut-off for these co-guanidine membranes was approximately 31 kDa, sufficient to exclude extracapsular nuclease. The level of DNA protection was found to be comparable to high molecular weight poly-L-lysine membranes (197.1 kDa). Intracapsular DNA was accessible to the carcinogen ethidium bromide, which showed a 4-fold increase in uptake in uncoated beads and 2-fold uptake in co-guanidine coated beads compared to beads lacking in DNA. Co-guanidine membranes coating alginate result in a molecular weight cut-off sufficient to retain DNA and exclude 31 kDa DNAse, while providing access to the low molecular weight carcinogen, ethidium bromide.

The factors which influence the steady state performance of a CSTR operation with microencapsulated urease for the regeneration of a dialysated solution have been studied at various enzyme activities. The theoretical model considered the effect of microcapsule diameter, pH-dependent kinetics, and product inhibition and substrate depletion, in relation to urea conversion and the capsule effectiveness factor. The limiting effects of pH, product inhibition and substrate depletion were also studied individually and in combination under eight case studies. The base case which included these three limiting factors in the reaction process, predicted the lowest urea conversion values at the enzyme activities considered. However, the effectiveness factor for each case at a fixed microcapsule diameter depended on the enzyme activity. This behaviour was studied for two different microcapsule diameters, 5 microns and 500 microns. At enzyme activities lower than 1 mM/s, a model considering Michaelis-Menten kinetics alone, predicted the highest effectiveness factors. On the other hand, beyond 1 mM/s enzyme activity, the lowest effectiveness factors were predicted, although higher conversions than that of the base case were achieved. This might be due to the rapid depletion of substrate at high activities when Michaelis-Menten kinetics were considered, leads to residual substrate concentrations (Sr) lower than the Michaelis-Menten constant Km,o; a condition for a dramatic drop in the intraparticle reaction rate. The limiting factors in the base case held Sr at a relatively higher value than Km,o.

A 91.5% mass yield of urease and hemoglobin (Hb), co-encapsulated within polyamide membranes, was determined spectrophoto-metrically. The specific activity yield of microencapsulation was 84%, twofold higher than values previously reported, as a result of optimization of encapsulation conditions. The kinetic parameters and pH activity profiles of intracapsular urease were determined to be similar to those corresponding to the free enzyme. Similar activities were also observed for intact and microcapsule homogenate, indicating minimal mass transfer and diffusional limitation. The active configuration of the enzyme appears to remain intact upon microencapsulation. The application of a kinetic model for encapsulated urease further indicated that the kinetics were reaction-controlled with minimal mass transfer restrictions.

The mannoprotein which is a major component of the cell wall of Saccharomyces cerevisiae is an effective bioemulsifier. Mannoprotein emulsifier was extracted in a high yield from whole cells of fresh bakers' yeast by two methods, by autoclaving in neutral citrate buffer and by digestion with Zymolase (Miles Laboratories; Toronto, Ontario, Canada), a beta-1,3-glucanase. Heat-extracted emulsifier was purified by ultrafiltration and contained approximately 44% carbohydrate (mannose) and 17% protein. Treatment of the emulsifier with protease eliminated emulsification. Kerosene-in-water emulsions were stabilized over a broad range of conditions, from pH 2 to 11, with up to 5% sodium chloride or up to 50% ethanol in the aqueous phase. In the presence of a low concentration of various solutes, emulsions were stable to three cycles of freezing and thawing. An emulsifying agent was extracted from each species or strain of yeast tested, including 13 species of genera other than Saccharomyces. Spent yeast from the manufacture of beer and wine was demonstrated to be a possible source for the large-scale production of this bioemulsifier.