Free-Floating Bioelectronic Sensors for Fermentation Monitoring

The static, mounted monitoring systems currently used inside fermentation vats are poised to be replaced in the near future with a network of free-floating bioelectronic sensors, if the vision of researchers from Boston University and Capra Biosciences reaches fruition.

Designed for both vat and continuous bioprocessing systems, this bioelectronic sensor network could, ideally “provide spatial information about where they are in a heterogeneous bioreactor platform…as well as multiple measurements of things such as temperature, pH, dissolved oxygen, and dissolved carbon dioxide,” Rabia Yazicigil, PhD, associate professor, Boston University (BU), and lead principal investigator for this project, tells GEN.

Consequently, the network will report data that enable biomanufacturers to determine whether the solution is mixing properly and to identify transit times throughout the process, in addition to specific processing parameters.

“The key innovation…is that these systems integrate living cells into the electronics,” Miguel Jimenez, PhD, assistant professor, BU, emphasizes. The inclusion of microbes—bacteria or yeast cells, for example—“supercharges the sensors,” enabling them to monitor more parameters that are directly relevant to biomanufacturing.

Roughly the size of a chickpea, these sensors never leave the bioreactor. “That allows us to get measurements throughout the reactor… which helps us build a really rich data set that we can then feed into models to help us monitor and predict performance,” notes Mark Poole, PhD, senior director of manufacturing and applied AI, Capra Biosciences.

Paradigm-shifting potential

“Having lots of high-quality measurements at different points in the reactor is game-changing for any biomanufacturing company,” Poole says.

Jon Valdez, program manager at BioMADE, which funded the project as part of a $21.4 million investment in 14 projects to advance the bioindustrial manufacturing industry, agrees, calling it potentially paradigm-shifting. Potential applications extend to clinical monitoring—where a prior collaboration focused on human gut monitoring. The technology is solvent-agnostic but may be most effective in a water-based environment, enabling applications that may include soil and water quality monitoring. Benefits, he says, include lower costs per sensor (estimated at $10−$100) and decreased risk of contamination.

The project is two-tiered. The first tier, the electronics-only sensor, is the nearest to commercialization. Industrial-scale testing will be conducted soon at Capra facilities. “That [alone] would signify a big advance,” Jimenez says, citing the ability to field networked sensors capable of measuring multiple conditions throughout a bioreactor or continuous production process.

The second tier adds the bio component to those sensors. This feature is in academic development. Primary challenges are how to design biohybrid sensors that can be autoclaved or cleaned-in-place, and strategies to stabilize and encapsulate the microbes to be compatible with industrial requirements. The researchers are considering possible approaches now.

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