Operator training in recombinant protein production using a structured simulator model.

Area of Science:

• Biotechnology and bioprocess engineering
• Chemical engineering
• Microbial fermentation technology

Background:

• Operator training is crucial for efficient and safe recombinant protein production.
• Existing training methods may not adequately prepare personnel for critical bioprocess events.
• Model-based operator training simulators (OTS) offer a potential solution for virtual skills development.

Purpose of the Study:

• To develop and evaluate a model-based OTS for training operators in recombinant protein production processes.
• To ensure the simulation model accurately represents critical bioprocess events for effective training.
• To assess the impact of OTS training on operator performance in real bioprocesses.

Main Methods:

• Development of a structured multi-compartment model for Escherichia coli fed-batch processes.
• Highlighting critical events such as induction, stress effects, and overflow metabolism within the model.
• Application of the model on an OTS platform for virtual simulation of bioreactor operations.
• Comparative evaluation of trained versus untrained operator groups performing laboratory-scale cultivations.

Main Results:

• The model-based OTS successfully simulated operational bioreactor procedures in real or accelerated time.
• Operators trained using the OTS demonstrated improved capabilities compared to untrained groups.
• Trained operators showed enhanced performance when subsequently conducting real laboratory-scale cultivations.

Conclusions:

• Model-based OTS is a valuable tool for virtual training of bioprocess operators.
• The developed simulation model effectively trains operators on critical events in recombinant protein manufacturing.
• OTS training can significantly enhance operator skills, contributing to improved large-scale bioprocess outcomes.