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ESSENTIAL GUIDE TO PROTEIN SYNTHESISIN BIOREACTORSMastering Protein Synthesis Advances
Biotechnology
Protein synthesis is an example of the advancements made in biotechnological applications.
This process harnesses life's intricate mechanisms to manufacture complex and specificsubstances. Understanding and manipulating protein synthesis principles, scientists haveengineered cells to produce desired proteins, developed novel biomaterials and biocatalysts,
and created targeted drug therapies. Advances in protein synthesis have also enabled
the production of valuable compounds through metabolic engineering and opened up
possibilities for gene therapy and protein engineering.
Proteins serve as multifunctional biomolecules, essential for catalytic reactions, structuralintegrity, defensive mechanisms, and regulatory processes within the cell. The protein
production process involves transcribing DNA codes to RNA, which are then translated
into proteins. These proteins are folded into functional shapes and often further modified
through glycosylation.
The quality and yield of protein synthesis depend on the orchestration of numerous
parameters, including gene expression systems, host cell lines, nutrient composition,
environmental conditions, and precise control of operational factors. Advances inunderstanding and manipulating these parameters have improved protein production.
Deciphering protein synthesis mechanisms has also identified drug development targets,
such as antibiotics that inhibit bacterial protein synthesis or drugs that modulate protein
production in human cells.

The selection of the organism (the “expression system”) for protein production, whether utilizing
human or animal cell cultures or microorganisms like bacteria and fungi through fermentation, rests on
certain critical requirements:›P roduction Costs: If budget constraints are a concern, bacteria, plant cells, or fungi are typically morecost-effective.
›P rotein Glycosylation and Folding: The complexity of the protein's post-translational modifications,particularly glycosylation and proper folding, is pivotal.
While bacteria can rapidly and inexpensively produce protein in high volumes, but often fail to achievecorrect glycosylation or folding. This results in non-functional proteins. Bacteria can produce highvolumes of protein quickly and cheaply, but often fail to achieve correct glycosylation or folding,resulting in non-functional proteins.
Proteins that require extensive post-translational modification, yeast expression systems may be
preferred due to their eukaryotic characteristics. When human-like glycosylation patterns are required,insect or mammalian cells are the most common choice due to their closer biological resemblance
to human cells. Bioreactors, such as those offered by IKA, afford higher control over the cellularenvironment than traditional methods, which is crucial during protein synthesis for achieving thedesired protein functionality.
Enzymes(industrial use, diagnostic
products, biotechnologyapplications)

Antigens (Vaccines)DNA:building plan
Antibodies(Medical treatments,diagnostic products)

mRNA:
working copy
DNA
Folding &Glycosylation

Food additives

cell
GENETIC ENGINEERING:
Manipulated DNA can be introduced into
an organism to produce a protein of interest

Protein:product

Bioreactor

Hormones (insulin)

Figure Legend: Major Protein Products from Bioreactors.

Essential Guide to Protein Synthesis in Bioreactors | 2

Essential
Essential
GuideGuideto Protein
to Fermentation
Synthesis in Bioreactors | 3

What is a Bioreactor?
A bioreactor is an advanced equipment crucial

Systems like the IKA HABITAT bioreactor arefor modern biotechnological innovation andpivotal in transitioning protein production fromintegral to the field of protein synthesis. These

small-scale laboratory settings to large-scaleprecision devices, equipped with the latest

industrial manufacturing. They offer enhanced

sensors and control systems, are designed tofeatures that improve the quality and yield

regulate environmental parameters such asof synthesized proteins, making large-scaletemperature, pH, and oxygen levels, creatingproduction feasible. Bioreactors provide precise

ideal conditions for protein production incontrol over the cellular environment, allowing

various expression systems.

optimization of conditions for proper protein
folding and post-translational modifications.

/// Importance of a Bioreactor for Protein
Synthesis
While traditional culture systems often cannot regulate variable external conditions, bioreactors areequipped with sophisticated control systems that precisely regulate all environmental parameters.
This precision creates optimal conditions for cell function and protein expression, which are often
difficult to achieve with traditional techniques. As a result, bioreactors produce proteins of higher
quality, with more consistency, and in greater amounts than those yielded by standard methods.
Scalability is another key advantage of using a bioreactor. Processes can be scaled from research toindustrial production more effectively than with flasks or dishes that offer limited control and areprone to variability. This scalability, coupled with automation, provides consistent conditions across allproduction levels to maintain protein quality and yield.
Bioreactors also reduce the risk of contamination, resulting in purer protein products essential forcertain applications. While traditional culturing can produce proteins adequate for research, it often
lacks the consistency required for therapeutic protein manufacturing.

/// Diversity of Protein Products
in Bioreactor Systems› Enzymes(e.g. used in detergents, paper production)› Hormones (e.g. insulin, erythropoietin & glucagon)› Human serum albumin (HSA)› Vaccines against hepatitis or human papillomavirus (produced in yeast)› Protein-based drugs & monoclonal antibodies› Proteins as a food source or meat alternative, such as single-cell proteins(SCP) produced in algae** Single-cell proteins (SCP) refer to edible
unicellular microorganisms.

Essential Guide to Protein Synthesis in Bioreactors | 4

Essential Guide to Protein Synthesis in Bioreactors | 5

/// Why IKA HABITAT Bioreactors
are Optimal to Support Protein
Synthesis

Precise environmental control for cell cultivation
Mass flow controllers precisely regulate the input of air, nitrogen, and oxygen,optimizing cell growth. Dissolved oxygen (DO) levels are a critical parameter in thisprocess.
A dedicated carbon dioxide supply system maintains optimal pH levels, whileheadspace gassing options facilitate efficient oxygen transfer with minimal cellularperturbation. This precise control over the cell culture environment promotes
consistent and reproducible experimental results.

Advanced monitoring with next generation sensors
Advanced sensors for comprehensive bioprocess monitoring, including newgeneration sensors for biomass, cell viability, and off-gas analysis, offer highselectivity, sensitivity, and long-term stability. These sensors enable contaminationfree bioprocessing and improved operator efficiency by monitoring dissolved
carbon dioxide, conductivity, turbidity, Redox, cell viability, off-gas, temperatures,and non-intrusive foam.
Soft-sensors can be used to calculate and display specific batch data, such asparameter setpoints, organism-specific rates (μ, qs, RQ, etc.), and extended batchvalues (culture broth weight, biomass).

Reducing shear stress
IKA HABITAT Bioreactors have a reactor geometry with a pitched blade andimpeller design that ensures a gentle yet efficient mixing without the risk ofdamage from excessive shear forces. This approach optimizes the growth andmaintenance of suspension and sensitive adherent cells. A new chaotic mixing
mode that follows mathematical principles of chaotic-dynamic systems also
provides for a more homogeneous mixture.

Essential Guide to Protein Synthesis in Bioreactors | 62023/// How IKA HABITAT Bioreactors Enhance Lab Operations
IKA HABITAT Bioreactors are more than mere cultivation tools; they are integrated solutions designed to enhance operations withsmoother, more efficient workflows tailored to the dynamic needs of our customers.

Award-Winning Design

Solutions that Scale

Recognized with the iF DESIGN AWARD 2023, the IKA
HABITAT Bioreactor integrates the capabilities of a bioreactor,photobioreactor, and fermenter, reducing the need for multiple
setups and switching. Its ergonomic handling, intuitive
operation, and user-friendly features, such as an open skid,
unique lid stand, and lightweight components, reduce operator
fatigue and improve portability. The compact design maximizes
bench space. The bioreactor's intelligent support systems andcontrols make it accessible to both beginners and experts.

IKA HABITAT Bioreactors excel from micro-scale research toindustrial production. They feature a chaotic mixing option forfaster mixing, an advantage especially beneficial at the beginningof an experiment. The bioreactor’s design includes a range ofvessel volumes from 0.5L to 10L, available in both single anddouble-wall configurations. Properly-sized motors for eachvolume—small for up to 2L, and larger for 5L to 10L—ensure
efficient operation and customization in contrast to the standard
one-size-fits-all motor approach. Advanced, integrated control
systems guarantee consistent scale-up processes, enabling
seamless capacity growth.

Consistent Quality
The IKA HABITAT Bioreactor sets the benchmark for consistentquality in bioprocessing by ensuring that each production
cycle meets the high standards expected in the industry.
Its sophisticated control systems and precision engineering
provide a dependable foundation for operations, guaranteeing
uniform outputs that streamline the entire downstream process.
Variable-speed, bi-directional peristaltic pumps and an optional
fifth pump provide for diverse fluid management. This fidelity
in performance facilitates the scalability of production andsignificantly reduces the occurrence of batch failures, mitigating
downtime and waste.

Cross-Platform Integration
OPC UA integration and extensive interface options includingUSB, Ethernet, and RS-232 to provide comprehensive dataconnectivity. The lid's additional ports enable customized
modifications to accommodate a range of bioprocessing
applications.

Global Presence, Local Support
IKA's global presence provides comprehensive support,
including technical service, spare parts, calibration, qualification,and commissioning, empowering customers to achieve theirbioprocessing goals.
Essential Guide to Protein Synthesis in Bioreactors | 7

United Kingdom

Germany
PolandUSA

ThailandTurkey

China

Spain

Uganda

Japan

India

Kenya
Korea

MalaysiaBrazil

VietnamGlobal Partner for BioProcessing Solutions
GERMANY
IKA-Werke GmbH & Co. KG
StaufenPhone: +49 7633 831-0
sales@ika.de

MALAYSIA
IKA Works (Asia) Sdn Bhd
Kuala Lumpur (Rawang)
Phone: +60 3 6099-5666
sales.lab@ika.my

INDIA
IKA India Private Limited
Bangalore
Phone: +91 80 26253 900
info@ika.inUSA
IKA Works, Inc.
Willmington
Phone: +1 910 452-7059
sales@ika.net

CHINA
IKA Works Guangzhou
Guangzhou
Phone: +86 20 8222 6771
info@ika.cn

BRASILIKA Brasil
Campinas/Rio de Janero
Phone: +55 19 3772-9600
sales@ika.net.br

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