Production of recombinant human interferon-alpha 1 by Escherichia coli using a computer-controlled cultivation process.

Genetically engineered E. coli K12 BMH-71-18 with plasmid PBV-867 was used for constitutive expression of human interferon-alpha 1 (IFN) with a defined medium. A manual, time-based, fed-batch cultivation process produced a cell density of 26.3 g l-1 (OD550 89), an IFN activity of 1.55 x 10(8) IU l-1 and a specific IFN productivity of 0.65 x 10(6) IU g-1. An analysis was conducted to characterize the problems involved in the high density microbial processes of recombinant protein production. The strategy suggested by the analysis is to establish a nutrient feeding profile that improves both the plasmid stability and the overall productivity of IFN. The nutrient feeding procedure developed here was based on the growth dynamics and a glucose consumption model. By using this procedure to continuously supply nutrients during cultivations, cell density reached 58 to 80 g l-1 and the specific IFN productivities of these runs were increased over that of the manual process. Nutrient feeding rates were found to affect the specific IFN productivity substantially. The optimized process achieved an IFN activity of 1.26 x 10(9) IU l-1, a cell density of 58 g l-1 and a specific IFN productivity of 2.2 x 10(7) IU g-1. More significantly, the overall productivity IU l-1 h-1 of the optimized, computer-controlled cultivation process was increased 12.9-fold over that of the manual cultivation process.