U.S. patent application number 15/106379 was filed with the patent office on 2016-11-03 for processes for obtaining microbial oil from microbial cells.
This patent application is currently assigned to DSM IP ASSETS B.V.. The applicant listed for this patent is Xiao DONG, Neil Francis LEININGER, Vidya PAI, Joseph William PFEIFER, III, Ginger SHANK. Invention is credited to Xiao DONG, Neil Francis LEININGER, Vidya PAI, Joseph William PFEIFER, III, Ginger SHANK.
Application Number | 20160319218 15/106379 |
Document ID | / |
Family ID | 53403738 |
Filed Date | 2016-11-03 |
United States Patent
Application |
20160319218 |
Kind Code |
A1 |
LEININGER; Neil Francis ; et
al. |
November 3, 2016 |
PROCESSES FOR OBTAINING MICROBIAL OIL FROM MICROBIAL CELLS
Abstract
Disclosed herein are processes for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells by lysing the cells to form a lysed cell
composition, treating the lysed cell composition to form an
oil-containing emulsion and then recovering the oil from the
oil-containing emulsion. Further disclosed herein is microbial oil
comprising one or more PUFAs that is recovered from microbial cells
by at least one process described herein.
Inventors: |
LEININGER; Neil Francis;
(Winchester, KY) ; SHANK; Ginger; (Winchester,
KY) ; DONG; Xiao; (Woodstock, MD) ; PFEIFER,
III; Joseph William; (Westminster, MD) ; PAI;
Vidya; (Columbia, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LEININGER; Neil Francis
SHANK; Ginger
DONG; Xiao
PFEIFER, III; Joseph William
PAI; Vidya |
Winchester
Winchester
Woodstock
Westminster
Columbia |
KY
KY
MD
MD
MD |
US
US
US
US
US |
|
|
Assignee: |
DSM IP ASSETS B.V.
TE Heerlen
NL
|
Family ID: |
53403738 |
Appl. No.: |
15/106379 |
Filed: |
December 19, 2014 |
PCT Filed: |
December 19, 2014 |
PCT NO: |
PCT/US14/71469 |
371 Date: |
June 20, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61919000 |
Dec 20, 2013 |
|
|
|
62093986 |
Dec 18, 2014 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C07C 51/487 20130101;
C11B 3/001 20130101; C07C 51/42 20130101; C11B 1/02 20130101; C11B
1/025 20130101; C07C 51/487 20130101; C07C 57/03 20130101; C07C
51/42 20130101; C07C 57/03 20130101 |
International
Class: |
C11B 1/02 20060101
C11B001/02; C11B 3/00 20060101 C11B003/00 |
Claims
1. A process for obtaining a microbial oil comprising one or more
polyunsaturated fatty acids from one or more microbial cells,
wherein the process comprises: (a) lysing the cells comprising the
microbial oil to form a lysed cell composition; (b) treating the
lysed cell composition to form an oil-containing emulsion; (c)
separating the oil-containing emulsion from the lysed cell
composition; (d) demulsifying the oil-containing emulsion; and (e)
recovering the oil.
2. The process of claim 1, wherein at least one of (a) or (b)
further comprises raising the pH of the cells or the lysed cell
composition.
3. The process of claim 2, wherein at least one of (a) or (b)
further comprises raising the pH to about 7 or above.
4. The process of claim 1, wherein at least one of (a) or (b)
further comprises raising the pH from about 7 to about 11.
5. The process of claim 1, wherein (a) further comprises
controlling the pH of the cells.
6. The process of claim 5, wherein controlling the pH of the cells
comprises adding a base.
7. The process of claim 1, wherein at least one of (a) or (b)
further comprises agitating the cells or the lysed cell
composition.
8. The process of claim 1, wherein at least one of (a) or (b)
further comprises heating the cells or the lysed cell composition
to at least 50.degree. C.
9. The process of claim 1, wherein at least one of (a) or (b)
further comprises heating the cells or the lysed cell composition
from about 50.degree. C. to about 100.degree. C.
10. The process of claim 1, wherein (a) further comprises adding an
enzyme in an amount of from about 0.05% to about 20% by weight of
the cell broth.
11. The process of claim 1, wherein (b) further comprises adding a
salt in an amount of from about 0.05% to about 20% by weight of the
cell broth.
12. The process of claim 11, wherein the salt is selected from the
group consisting of alkali metal salts, alkali earth metal salts,
sulfate salts, and combinations thereof.
13. The process of claim 1, wherein the cells of (a) are
unwashed.
14. The process of claim 1, wherein the cells of (a) are contained
in a fermentation broth.
15. The process of claim 1, wherein (c) further comprises heating
the oil-containing emulsion and the lysed cell composition to at
least 50.degree. C.
16. The process of claim 1, wherein (c) further comprises heating
the oil-containing emulsion and the lysed cell composition from
about 50.degree. C. to about 100.degree. C.
17. The process of claim 1, wherein (c) further comprises
centrifuging.
18. The process of claim 1, wherein (d) further comprises heating
the oil-containing emulsion to at least 50.degree. C.
19. The process of claim 1, wherein (d) further comprises heating
the oil-containing emulsion from about 50.degree. C. to about
100.degree. C.
20. The process of claim 1, wherein (d) further comprises adding an
acid.
21. The process of claim 20, wherein the acid comprises citric
acid.
22. The process of claim 1, wherein (d) further comprises adding a
base.
23. The process of claim 22, wherein the base comprises sodium
hydroxide.
24. The process of claim 1, wherein the polyunsaturated fatty acid
is selected from an omega-3 fatty acid, an omega-6 fatty acid, and
mixtures thereof.
25. The process of claim 1, wherein the polyunsaturated fatty acid
is selected from docosahexaenoic acid (DHA), eicosapentaenoic acid
(EPA), docosapentaenoic acid (DPA), arachidonic acid (ARA),
gamma-linolenic acid (GLA), dihomo-gamma-linolenic acid (DGLA),
stearidonic acid (SDA), and mixtures thereof.
26. The process of claim 25, wherein the polyunsaturated fatty acid
is docosahexaenoic acid (DHA).
27. The process of claim 25, wherein the polyunsaturated fatty acid
is arachidonic acid (ARA).
28. The process of claim 1, wherein the microbial cells are algae,
yeast, fungi, protest, or bacteria cells.
29. The process of claim 1, wherein the microbial cells are from
the genus Mortierella, genus Crypthecodinium, or order
Thraustochytriales.
30. The process of claim 29, wherein the microbial cells are from
the order Thraustochytriales.
31. The process of claim 29, wherein the microbial cells are from
the genus Thraustochytrium, Schizochytrium, or mixtures
thereof.
32. The process of claim 29, wherein the microbial cells are from
Mortierella Alpina.
33. The process of claim 1, wherein the lysed cell composition
comprises liquid, cell debris, and microbial oil.
34. The process of claim 1, wherein an organic solvent is not used
to obtain the oil from the cells.
35. The process of claim 1, wherein (e) further comprises
centrifuging the oil.
36. The process of claim 1, wherein (e) further comprises refining
the oil.
37. The process of claim 1, wherein the oil comprises at least 30%
by weight arachidonic acid.
38. The process of claim 1, wherein the oil comprises at least 30%
by weight docosahexaenoic acid.
39. The process of claim 1, wherein the oil has an anisidine value
of less than about 50.
40. The process of claim 1, wherein the oil has a phosphorus
content of about 8 ppm or less.
41. The process of claim 1, wherein the oil has a peroxide value of
less than about 5 meq/kg.
42. An oil obtained by the process of claim 1.
43. The process of claim 1, wherein (a) and (b) are combined
together to form a one-step lysing and treating step.
44. A process for obtaining a microbial oil comprising one or more
polyunsaturated fatty acids from one or more microbial cells,
wherein the process comprises: (a) lysing the cells comprising the
microbial oil to form a lysed cell composition; (b) treating the
lysed cell composition to form an oil-containing emulsion; (c)
separating the oil-containing emulsion from the lysed cell
composition; and (d) demulsifying the oil-containing emulsion; and
(e) recovering the oil, wherein at least one of (a) and (b)
comprises raising the pH of the cells or lysed cell composition,
agitating the cells or lysed cell composition, and heating the
cells or lysed cell composition.
45. The process of claim 44, wherein (a) further comprises adding
an enzyme in an amount of from about 0.05% to about 20% by weight
of the cell broth.
46. The process of claim 44 or claim 45, wherein (b) further
comprises adding a salt in an amount of from about 0.05% to about
20% by weight of the cell broth.
47. The process of claim 44, wherein (c) further comprises heating
the oil-containing emulsion and the lysed cell composition to at
least 50.degree. C.
48. The process of claim 44, wherein (c) further comprises
centrifuging.
49. The process of claim 44, wherein (d) further comprises at least
one of heating to at least 50.degree. C., adding an acid, and
adding a base.
50. The process of claim 44, wherein (e) further comprises
centrifuging the oil.
51. The process of claim 44, wherein (e) further comprises refining
the oil.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. Provisional Patent Application No. 61/919,000 filed Dec. 20,
2013 and 62/093,986 filed Dec. 18, 2014, the disclosure of which is
hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Disclosed herein are processes for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells by lysing the cells to form a lysed cell
composition, treating the lysed cell composition to form an
oil-containing emulsion and then recovering the oil from the
oil-containing emulsion. Further disclosed herein is a microbial
oil comprising one or more PUFAs that is recovered from microbial
cells by at least one process described herein.
[0003] Microbial oil containing one or more PUFAs is produced by
microorganisms, such as, for example, algae and fungi.
[0004] A typical process for obtaining PUFA containing oil from
microbial cells involves growing microorganisms that are capable of
producing the desired oil in a fermentor, pond or bioreactor to
produce a microbial cell biomass; separating the biomass from the
fermentation medium in which the biomass was grown; drying the
microbial cell biomass, using a water-immiscible organic solvent
(e.g., hexane) to extract the oil from the dried cells; and
removing the organic solvent (e.g., hexane) from the oil. This
process can further involve diluting the fermentation medium
containing the cell biomass with water followed by centrifugation
to separate the biomass from the diluted fermentation medium.
[0005] Another process for obtaining PUFA containing oil from
microbial cells involves growing microorganisms that fare capable
of producing the desired oil in a fermentor, pond or bioreactor to
produce a microbial cell biomass; releasing the PUFA containing oil
into the fermentation medium in which the cells were grown by using
mechanical force (e.g., homogenization), enzymatic treatment, or
chemical treatment to disrupt the cell walls; and recovering the
oil from the resulting composition comprising PUFA containing oil,
cell debris, and liquid using a water miscible organic solvent,
e.g., isopropyl alcohol. The oil can be separated mechanically from
the composition and the alcohol must be removed from both the oil
and the aqueous biomass waste stream.
[0006] The industrial scale employment of either of the above
processes for obtaining PUFA containing oils from microbial cells
requires the use of a large amount of volatile and flammable
organic solvent, which creates hazardous operating conditions and
requires the use of expensive explosion-proof equipment.
Additionally, the use of an organic solvent generates an organic
solvent waste stream that requires implementation of an expensive
solvent recovery process to address the strict environmental limits
on volatile organic compound (VOC) emissions, which in turn results
in the need for more manpower and costly equipment.
[0007] Further, the use of heat in the above processes to dry the
cells and/or remove the solvent from the recovered oil can degrade
the PUFA containing oils and increase energy usage, which can
further increase processing costs. Degradation occurs when PUFA
containing oils are exposed to oxygen such as when the integrity of
the microbial cell walls is disrupted and/or the microbial cells
are exposed to heat.
[0008] A solvent-free process for obtaining PUFA containing oil
from microbial cells involves growing microorganisms that are
capable of producing the desired oil in a fermentor, pond or
bioreactor to produce a microbial cell biomass; releasing the PUFA
containing oil into the fermentation medium in which the cells were
grown by using mechanical force (e.g., homogenization), enzymatic
treatment, or chemical treatment to disrupt the cell walls; and
recovering crude oil from the resulting composition comprising PUFA
containing oil, cell debris, and liquid by raising the pH adding a
salt, heating, and/or agitating the resulting composition. This
solvent-free process for obtaining PUFA containing oil from cells,
however, can require long oil recovery times, large amounts of
salt, and/or many steps, which can all increase processing
costs.
[0009] As a result, there remains a need for a process for
obtaining high quality PUFA containing oils from microbial cells
that does not use a volatile organic solvent, can be performed
using readily available equipment, requires a minimum number of
steps, has shorter oil recovery times, and can provide a high yield
of high quality PUFA containing oil.
[0010] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0011] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0012] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0013] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0014] (d) demulsifying the oil-containing emulsion; and
[0015] (e) recovering the oil.
[0016] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0017] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0018] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0019] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0020] (d) demulsifying the oil-containing emulsion; and
[0021] (e) recovering the oil,
wherein at least one of (a) or (b) further comprises raising the pH
of the cells or lysed cell composition.
[0022] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0023] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0024] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0025] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0026] (d) demulsifying the oil-containing emulsion; and
[0027] (e) recovering the oil,
wherein at least one of (a) or (b) further comprises heating the
cells or lysed cell composition to at least 50.degree. C.
[0028] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0029] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0030] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0031] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0032] (d) demulsifying the oil-containing emulsion; and
[0033] (e) recovering the oil,
wherein at least one of (a) or (b) further comprises agitating the
cells or lysed cell composition.
[0034] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0035] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0036] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0037] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0038] (d) demulsifying the oil-containing emulsion; and
[0039] (e) recovering the oil,
wherein (a) further comprises adding an enzyme.
[0040] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
(a) lysing the cells comprising the microbial oil to form a lysed
cell composition; (b) treating the lysed cell composition to form
an oil-containing emulsion; (c) separating the oil-containing
emulsion from the lysed cell composition; (d) demulsifying the
oil-containing emulsion; and (e) recovering the oil, wherein (b)
further comprises adding a salt.
[0041] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0042] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0043] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0044] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0045] (d) demulsifying the oil-containing emulsion; and
[0046] (e) recovering the oil,
wherein (c) further comprises centrifuging.
[0047] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0048] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0049] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0050] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0051] (d) demulsifying the oil-containing emulsion; and
[0052] (e) recovering the oil,
wherein (d) further comprises at least one of heating to at least
50.degree. C., adding an acid and adding a base.
[0053] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0054] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0055] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0056] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0057] (d) demulsifying the oil-containing emulsion; and
[0058] (c) recovering the oil,
wherein at least one of (a) and (b) comprises raising the pH of the
cells or lysed cell composition, agitating the cells or lysed cell
composition, and heating the cells or lysed cell composition.
[0059] Disclosed herein is a microbial oil obtained by any of the
processes described herein.
[0060] The features and advantages of the invention may be more
readily understood by those of ordinary skill in the art upon
reading the following detailed description. It is to be appreciated
that certain features of the invention that are, for clarity
reasons, described above and below in the context of separate
embodiments, may also be combined so as to form sub-combinations
thereof.
[0061] Embodiments identified herein as exemplary are intended to
be illustrative and not limiting.
[0062] The term "about" is intended to capture variations above and
below the stated number that may achieve substantially the same
results as the stated number.
[0063] Disclosed herein is a process for obtaining a microbial oil
comprising one or more polyunsaturated fatty acids (PUFAs) from one
or more microbial cells comprising
[0064] (a) lysing the cells comprising the microbial oil to form a
lysed cell composition;
[0065] (b) treating the lysed cell composition to form an
oil-containing emulsion;
[0066] (c) separating the oil-containing emulsion from the lysed
cell composition;
[0067] (d) demulsifying the oil-containing emulsion; and
[0068] (e) recovering the oil.
[0069] In some embodiments, at least one of (a) or (b) further
comprises raising the pH of the cells or lysed cell composition. In
some embodiments, at least one of (a) or (b) further comprises
agitating the cells or the lysed cell composition. In some
embodiments, at least one of (a) or (b) further comprises heating
the cells or lysed cell composition. In some embodiments, at least
one of (a) or (b) further comprises at least one of raising the pH
of the cells or lysed cell composition., agitating the cells or the
lysed cell composition, and heating the cells or lysed cell
composition.
[0070] In some embodiments, (a) further comprises adding an
enzyme.
[0071] In some embodiments, (b) further comprises adding a
salt.
[0072] In some embodiments, (c) further comprises heating. In some
embodiments, (c) further comprises centrifuging.
[0073] In some embodiments, (d) further comprises heating. In some
embodiments, (d) further comprises adding an acid. In some
embodiments, (d) further comprises adding a base. In some
embodiments, (d) further comprises adding an emulsifier.
[0074] In some embodiments, (e) further comprises centrifuging the
oil. In some embodiments, (e) further comprises refining the
oil.
[0075] Disclosed herein is a microbial oil obtained by any of the
processes described herein.
[0076] Fatty acids are classified based on the length and
saturation characteristics of the carbon chain. Fatty acids present
in a microbial oil can have from 4 to 28 carbon atoms and are
termed short chain, medium chain, or long chain fatty acids based
on the number of carbons present in the chain. Fatty acids are
termed saturated fatty acids when no double bonds are present
between the carbon atoms, and are termed unsaturated fatty acids
when double bonds are present. Unsaturated long chain fatty acids
are monounsaturated when only one double bond is present and are
polyunsaturated when more than one double bond is present.
[0077] The microbial oil described herein refers to oil that
comprises one or more PUFAs and is obtained from microbial
cells.
[0078] Polyunsaturated fatty acids (PUFAs) are classified based on
the position of the first double bond from the methyl end of the
fatty acid; omega-3 (n-3) fatty acids contain a first double bond
at the third carbon, while omega-6 (n-6) fatty acids contain a
first double bond at the sixth carbon. For example, docosahexaenoic
acid (DHA) is an omega-3 long chain polyunsaturated fatty acid
(LC-PUFA) with a chain length of 22 carbons and 6 double bonds,
often designated as "22:6n-3." In one embodiment, the PUFA is
selected from an omega-3 fatty acid, an omega-6 fatty acid, and
mixtures thereof. In another embodiment, the PUFA is selected from
LC-PUFAs. In a still further embodiment, the PUFA is selected from
docosahexaenoic acid (DHA), eicosapentaenoic acid (EPA),
docosapentaenoic acid (DPA), arachidonic acid (ARA),
gamma-linolenic acid (GLA), dihomo-gamma-linolenic acid (DGLA),
stearidonic acid (SDA), and mixtures thereof. In another
embodiment, the PUFA is selected from DHA, ARA, and mixtures
thereof. In a further embodiment, the PUFA is DHA. In yet a further
embodiment, the PUFA is ARA.
[0079] LC-PUFAs are fatty acids that contain at least 3 double
bonds and have a chain length of 18 or more carbons or 20 or more
carbons. LC-PUFAs of the omega-6 series include, but are not
limited to, di-homo-gammalinoleic acid (C20:3n-6), arachidonic acid
(C20:4n-6) ("ARA"), docosatetraenoic acid or adrenic acid
(C22:4n-6), and docosapentaenoic acid (C22:5n-6) ("DPA n-6"). The
LC-PUFAs of the omega-3 series include, but are not limited to,
eicosatrienoic acid (C20:3n-3), eicosatetraenoic acid (C20:4n-3),
eicosapentaenoic acid (C20:5n-3) ("EPA"), docosapentaenoic acid
(C22:5n-3), and docosahexaenoic acid (C22:6n-3). The LC-PUFAs also
include fatty acids with greater than 22 carbons and 4 or more
double bonds including, but not limited to, C24:6(n-3) and
C28:8(n-3).
[0080] The PUFAs can be in the form of a free fatty acid, salt,
fatty acid ester (e.g. methyl or ethyl ester), monoacylglycerol
(MAG), diacylglycerol (DAG), triacylglycerol (TAG), and/or
phospholipid (PL).
[0081] Highly unsaturated fatty acids (HUFAs) are omega-3 and/or
omega-6 polyunsaturated fatty acids that contain 4 or more
unsaturated carbon-carbon bonds.
[0082] As used herein, a "cell" refers to an oil-containing
biomaterial, such as biomaterial derived from oleaginous
microorganisms. Oil produced by a microorganism or obtained from a
microbial cell is referred to as "microbial oil". Oil produced by
algae and/or fungi is also referred to as algal and/or fungal oil,
respectively.
[0083] As used herein, a "microbial cell" or "microorganism" refers
to organisms such as algae, bacteria, fungi, yeast, protist, and
combinations thereof, e.g., unicellular organisms. In some
embodiments, a microbial cell is a eukaryotic cell. A microbial
cell includes, but is not limited to, golden algae (e.g.,
microorganisms of the kingdom Stramenopiles); green algae; diatoms;
dinoflagellates (e.g., microorganisms of the order Dinophyceae
including members of the genus Crypthecodinium such as, for
example, Crypthecodinium cohnii or C. cohnii); microalgae of the
order Thraustochytriales; yeast (Ascomycetes or Basidiomycetes);
and fungi of the genera Mucor, Mortierella, including but not
limited to Mortierella alpina and Mortierella sect. schmuckeri, and
Pythium, including but not limited to Pythium insidiosum.
[0084] In one embodiment, the microbial cells are from the genus
Mortierella, genus Crypthecodinium, or order Thraustochytriales. In
a still further embodiment, the microbial cells are from
Crypthecodinium Cohnii. In yet an even further embodiment, the
microbial cells are selected from Crypthecodinium Cohnii,
Mortierella alpina, genus Thraustochytrium, genus Schizochytrium,
and mixtures thereof.
[0085] In a still further embodiment, the microbial cells include,
but are not limited to, microorganisms belonging to the genus
Mortierella, genus Conidiobolus, genus Pythium, genus Phytophthora,
genus Penicillium, genus Cladosporium, genus Mucor, genus Fusarium,
genus Aspergillus, genus Rhodotorula, genus Entomophthora, genus
Echinosporangium, and genus Saprolegnia. In another embodiment, ARA
is obtained from microbial cells from the genus Mortierella, which
includes, but is not limited to, Mortierella elongata, Mortierella
exigua, Mortierella hygrophila, Mortierella alpina, Mortierella
schmuckeri, and Mortierella minutissima. In a further embodiment,
ARA is obtained from microbial cells from Mortierella elongata
IFO8570, Mortierella exigua IFO8571, Mortierella hygrophila
IFO5941, Mortierella alpina IFO8568, ATCC16266, ATCC32221,
ATCC42430, CBS219.35, CBS224.37, CBS250.53, CBS343.66, CBS527.72,
CBS529.72, CBS608.70, and CBS754.68, and mutants thereof. In a
still further embodiment, the microbial cells are from Mortierella
alpina.
[0086] In an even further embodiment, the microbial cells are from
microalgae of the order Thraustochytriales, which includes, but is
not limited to, the genera Thraustochytrium (species include
arudimentale, aureum, benthicola, globosum, kinnei, motivum,
multirudimentale, pachydermum, proliferum, roseum, striatum); the
genera Schizochytrium (species include aggregatum, limnaceum,
mangrovei, minutum, octosporum); the genera Ulkenia (species
include amoeboidea, kerguelensis, minuta, profunda, radiate,
sailens, sarkariana, schizochytrops, visurgensis, yorkensis); the
genera Aurantiacochytrium; the genera Oblongichytrium; the genera
Sicyoidochytium; the genera Parientichytrium; the genera
Botryochytrium; and combinations thereof. Species described within
Ulkenia will be considered to be members of the genus
Schizochytrium. In another embodiment, the microbial cells are from
the order Thraustochytriales. In yet another embodiment, the
microbial cells are from Thraustochytrium. In still a further
embodiment, the microbial cells are from Schizochytrium. In a still
further embodiment, the microbial cells are chosen from genus
Thraustochytrium, Schizochytrium, or mixtures thereof.
[0087] In one embodiment, the process comprises lysing microbial
cells comprising a microbial oil to form a lysed cell composition.
The terms "lyse" and "lysing" refer to a process whereby the wall
and/or membrane of the microbial cell is ruptured. In one
embodiment, the microbial cell is lysed by being subjected to at
least one treatment selected from mechanical, chemical, enzymatic,
physical, and combinations thereof. In another embodiment, the
process comprises lysing the microbial cells comprising the
microbial oil to form a lysed cell composition, wherein the lysing
is selected from mechanical, chemical, enzymatic, physical, and
combinations thereof.
[0088] In some embodiments, prior to lysing the cell, the cell can
be washed and/or pasteurized. In some embodiments, washing the
cells includes using an aqueous solution, such as water, to remove
any extracellular water-soluble or water-dispersible compounds. In
some embodiments, the cell can be washed once, twice, thrice, or
more. In some embodiments, pasteurizing the cell includes heating
the cell to inactivate any undesirable enzymes, for example any
enzymes that might degrade the oil or reduce the yield of PUFAs. In
some embodiments, the cell is washed and then pasteurized before
being lysed. In some embodiments, the cells that are being lysed
are contained in a fermentation broth.
[0089] In some embodiments, the process comprises lysing unwashed
microbial cells comprising a microbial oil to form a lysed cell
composition. In some embodiments, a fermentation broth comprising
microbial cells comprising microbial oil is first washed with, for
example, water and then the cells lysed to form a lysed cell
composition. In other embodiments, the process comprises lysing
unwashed cells in a fermentation medium to form a lysed cell
composition.
[0090] Mechanical treatment includes, but is not limited to,
homogenization, ultrasound, cold-pressing, milling, and
combinations thereof. In some embodiments, the process comprises
lysing the cells by homogenization. In some embodiments, the
process comprises lysing the cell with a homogenizer.
[0091] Homogenization includes, but is not limited to, processes
that utilize a French cell press, sonicator, homogenizer,
microfluidizer, ball mill, rod mill, pebble mill, bead mill, high
pressure grinding roll, vertical shaft impactor, industrial
blender, high shear mixer, paddle mixer, polytron homogenizer,
industrial homogenizer (e.g., Niro Soavi VHP Homogenizer and APV
Rannie and APV Gaulin homogenizers), Industrial high shear fluid
processors (e.g., Microfluidics high shear fluid processor), cell
lysing/bead mill homogenizers (e.g., Dyno-Mill and Buhler), and
combinations thereof. In some embodiments, the cells flow through a
homogenizer that is optionally heated. In some embodiments,
suitable homogenization can include 1 to 3 passes through a
homogenizer at either high and/or low pressures.
[0092] In some embodiments, the pressure during homogenization is
150 bar to 1,400 bar; 150 bar to 1,200 bar; 150 bar to 900 bar; 150
bar to 300 bar; 300 bar to 1,400 bar; 300 bar to 1,200 bar; 300 bar
to 900 bar; 400 bar to 800 bar; 500 bar to 700 bar; or 600 bar. In
some embodiments, the pressure during homogenization is 2,000 psi
to 20,000 psi; 2,000 psi to 18,000 psi; 2,000 psi to 16,000 psi;
2,000 psi to 14,000 psi; 2,000 psi to 12,000 psi; 2,000 psi to
10,000 psi; 2,000 psi to 8,000 psi; 2,000 psi to 6,000 psi; 2,000
psi to 4,000 psi; 4,000 psi to 20,000 psi; 4,000 psi to 18,000 psi;
4,000 psi to 16,000 psi; 4,000 psi to 14,000 psi; 4,000 psi to
12,000 psi; 4,000 psi to 10,000 psi; 4,000 psi to 8,000 psi; 4,000
psi to 6,000 psi; 6,000 psi to 20,000 psi; 6,000 psi to 18,000 psi;
6,000 psi to 16,000 psi; 6,000 psi to 14,000 psi; 6,000 psi to
12,000 psi; 6,000 psi to 10,000 psi; 6,000 psi to 8,000 psi; 8,000
psi to 20,000 psi; 8,000 psi to 18,000 psi; 8,000 psi to 16,000
psi; 8,000 psi to 14,000 psi; 8,000 psi to 12,000 psi; 8,000 psi to
10,000 psi; 10,000 psi to 20,000 psi; 10,000 psi to 18,000 psi;
10,000 psi to 16,000 psi; 10,000 psi to 14,000 psi; 10,000 psi to
12,000 psi; 12,000 psi to 20,000 psi; 12,000 psi to 18,000 psi;
12,000 psi to 16,000 psi; 12,000 psi to 14,000 psi; 14,000 psi to
20,000 psi; 14,000 psi to 18,000 psi; 14,000 psi to 16,000 psi;
16,000 psi to 20,000 psi; 16,000 psi to 18,000 psi; or 18,000 psi
to 20,000 psi.
[0093] In some embodiments, the microbial cells are mixed in high
shear mixer before being homogenized. In some embodiments, the high
shear mixer is operated in a range of at least 5,000 rpm; at least
7,500 rpm; at least 10,000 rpm; at least 12,500 rpm; at least
15,000 rpm; 5,000 rpm to 15,000 rpm; 5,000 rpm to 12,500 rpm; 5,000
rpm to 10,000 rpm; 5,000 rpm to 7,500 rpm; 7,500 rpm to 15,000 rpm;
7,500 rpm to 12,500 rpm; 7,500 rpm to 10,000 rpm; 10,000 rpm to
15,000 rpm; 10,000 rpm to 12,500 rpm; or 12,500 rpm to 15,000
rpm.
[0094] Physical treatment includes, but is not limited to, heating,
which includes, but is not limited to, resistive, convection,
steam, fluid bath, solar, and combinations thereof. In some
embodiments, the cells are heated in a tank with resistive coils
in/on its walls. In some embodiments, the cells are heated in a
liquid bath with tubes passing there through.
[0095] Chemical treatment includes, but is not limited to, raising
the pH of the cells; lowering the pH of the cells; contacting the
cells with a chemical; and combinations thereof.
[0096] In some embodiments, the cells are lysed by raising the pH
of the cells. In some embodiments, the pH is raised by adding a
base. The bases include, but are not limited to, hydroxides (e.g.,
LiOH, NaOH, KOH, and Ca(OH).sub.2, and combinations thereof);
carbonates (e.g., Na.sub.2CO.sub.3, K.sub.2CO.sub.3, MgCO.sub.3,
and combinations thereof); bicarbonates (e.g., LiHCO.sub.3,
NaHCO.sub.3, KHCO.sub.3, and combinations thereof); and
combinations thereof. The base can be in the form of a solid (e.g.,
crystals, granulates, and pellets); a liquid (e.g., an aqueous
solution); and combinations thereof.
[0097] In some embodiments, the base has a pK.sub.b of 1 to 12, 1
to 10, 1 to 8, 1 to 6, 1 to 5, 2 to 12, 2 to 10, 2 to 8, 2 to 6, 2
to 5, 3 to 10, 3 to 6, 3 to 5, 4 to 10, 4 to 8, 4 to 6, 5 to 10, or
5 to 8. As used herein, the term "pK.sub.b" refers to the negative
logarithm of the base association constant, K.sub.b, of the base.
K.sub.b refers to the equilibrium constant for the ionization of
the base in water, wherein:
B + H 2 O HB + + OH - ; ##EQU00001## and the ##EQU00001.2## K b of
base , B , is defined as : K b = [ HB + ] [ OH - ] [ B ] .
##EQU00001.3##
[0098] In some embodiments, a base is added in an amount of about
2% to about 10%, about 2% to about 9%, about 2% to about 8%, about
2% to about 7%, about 2% to about 6%, about 3% to about 6%, about
4% to about 6%, about 5% to about 6%, about 2% to about 5%, about
2% to about 4%, about 2% to about 3%, about 3% to about 5%, about
3% to about 4%, or about 4% to about 5% by weight (or volume) of
the cell broth to raise the pH.
[0099] In some embodiments, the pH of the cells can be raised by a
chloralkali process. In some embodiments, the fermentation broth
containing sodium chloride and the cells is subjected to
electrolysis that results in the formation of sodium hydroxide,
which raises the pH of the cell. In some embodiments, the
fermentation broth includes calcium chloride or potassium chloride
instead of, or in addition to, sodium chloride, and electrolysis
results in the formation of calcium hydroxide or potassium
hydroxide, respectively, thereby raising the pH of the cell.
[0100] In some embodiments, the cells are lysed by lowering the pH
of the cells. In some embodiments, the pH is lowered by adding an
acid. The acids include, but are not limited to, sulfuric;
phosphoric; hydrochloric; hydrobromic; hydroiodic; hypochlorous;
chlorous; chloric; perchloric; fluorosulfuric; nitric;
fluoroantimonic; fluoroboric; hexafluorophosphoric; chromic; boric;
acetic; citric; formic; and combinations thereof.
[0101] Enzymatic treatment refers to contacting the cells with one
or more enzymes. Enzymes include, but are not limited to,
proteases, cellulases, hemicellulases, chitinases, pectinases, and
combinations thereof. Non-limiting examples of proteases include
serine proteases, theronine proteases, cysteine proteases,
aspartate proteases, metalloproteases, glutamic acid proteases,
alacase, and combinations thereof. Non-limiting examples of
cellulases include sucrase, maltase, lactase, alpha-glucosidase,
beta-glucosidase, amylase, lysozyme, neuraminidase, galactosidase,
alpha-mannosidase, glucuronidase, hyaluronidase, pullulanase,
glucocerebrosidase, galactosylceramidase, acetylgalactosaminidase,
fucosidase, hexosaminidase, iduronidase, maltase-glucoamylase, and
combinations thereof. A non-limiting example of a chitinase
includes chitotriosidase. Non-limiting examples of pectinases
include pectolyase, pectozyme, polygalacturonase, and combinations
thereof. In some embodiments, some enzymes are activated by
heating. In some embodiments, lysis does not include the use of
enzymes.
[0102] As used herein, a "lysed cell composition" refers to a
composition comprising one or more lysed cells, including cell
debris and other contents of the cell, in combination with
microbial oil (from the lysed cells), and optionally, a
fermentation broth that contains liquid (e.g., water), nutrients,
and microbial cells. In some embodiments, a microbial cell is
contained in a fermentation broth or media comprising water. In
some embodiments, a lysed cell composition refers to a composition
comprising one or more lysed cells, cell debris, microbial oil, the
natural contents of the cell, and aqueous components from a
fermentation broth. In one embodiment, the lysed cell composition
comprises liquid, cell debris, and microbial oil. In some
embodiments, a lysed cell composition is in the form of an
oil-in-water emulsion comprising a mixture of a continuous aqueous
phase and a dispersed oil phase. In some embodiments, a dispersed
oil phase is present in a concentration of about 1% to about 60%;
about 1% to about 50%; about 1% to about 40%; about 1% to about
30%; about 1% to about 20%; about 5% to about 60%; about 5% to
about 50%; about 5% to about 40%; about 5% to about 30%; about 5%
to about 20%; about 10% to about 60%; about 10% to about 50%; about
10% to about 40%; about 20% to about 60%; 20% to 50%, 20% to about
40%; about 30% to about 60%; about 30% to about 50%; or about 40%
to about 60% by weight (or volume) of an emulsified lysed cell
composition.
[0103] In some embodiments, lysing microbial cells results in the
formation of an emulsion from endogenous materials in the cell or
cell biomass including, but not limited to, proteins,
phospholipids, carbohydrates, and combinations thereof. The terms
"emulsion" and "emulsified" refers to a mixture of two or more
immiscible phases or layers wherein one phase or layer is dispersed
in another phase or layer. The terms "break," "break-up,"
"demulsify," "demulsification," "demulsifying," and "breaking"
refer to a process of separating immiscible phases or layers of an
emulsion. For example, in some embodiments, a process of the
present invention breaks an oil-containing emulsion from a
single-phase to two or more phases. In some embodiments, the two or
more phases include an oil phase and an aqueous phase. In some
embodiments, a process of the present invention breaks an
oil-containing emulsion into at least three phases. In some
embodiments, the three phases are selected from an oil phase, an
aqueous phase, and a solid phase. In some embodiments, the phases
are selected from an oil phase, an emulsion phase, an aqueous
phase, and a solid phase.
[0104] In some embodiments, the mean particle size of the oil
droplets formed during demulsification is selected from 5 microns
to 50 microns; 5 microns to 45 microns; 5 microns to 40 microns; 5
microns to 35 microns; 5 microns to 30 microns; 5 microns to 25
microns; 5 microns to 20 microns; 5 microns to 15 microns; 10
microns to 50 microns; 10 microns to 45 microns; 10 microns to 40
microns; 10 microns to 35 microns; 10 microns to 30 microns; 10
microns to 25 microns; 10 microns to 20 microns; 10 microns to 15
microns; 15 microns to 50 microns; 15 microns to 45 microns; 15
microns to 40 microns; 15 microns to 35 microns; 15 microns to 30
microns; 15 microns to 25 microns; 15 microns to 20 microns; 20
microns to 50 microns; 20 microns to 45 microns; 20 microns to 40
microns; 20 microns to 35 microns; 20 microns to 30 microns; 20
microns to 25 microns; 25 microns to 50 microns; 25 microns to 45
microns; 25 microns to 40 microns; 25 microns to 35 microns; 25
microns to 30 microns; 30 microns to 50 microns; 30 microns to 45
microns; 30 microns to 40 microns; 30 microns to 35 microns; 35
microns to 50 microns; 35 microns to 45 microns; 35 microns to 40
microns; 40 microns to 50 microns; 40 microns to 45 microns; and 45
microns to 50 microns. In a further embodiment, the mean particle
size of the oil droplets formed during demulsification is selected
from at least 10 microns, at least 15 microns, at least 20 microns,
at least 25 microns, at least 30 microns, at least 35 microns, and
at least 40 microns or above. In further embodiments, the mean
particle size of the oil droplets formed during demulsification is
selected from at least 10 microns, at least 15 microns, at least 20
microns, and at least 25 microns. In some embodiments, the mean
particle size can be measured using, e.g., a Beckman Coulter LS 13
320 particle size analyzer (Beckman Coulter, Brea, Calif.). In some
embodiments, the mean particle size can be measured using, e.g., a
Malvern MS2000 particle size analyzer (Malvern Instruments Ltd.,
Worcestershire, United Kingdom).
[0105] In some embodiments, the emulsifier is a detergent. In some
embodiments, the emulsifier is a surfactant. In some embodiments,
the emulsifier is added prior to, during, or after lysis. In one
embodiment, the emulsifier is added after lysis. In some
embodiments, the emulsifier is added to the lysed cell composition.
As used herein, the term "emulsifier" refers to a substance that
stabilizes an emulsion. Emulsifiers are selected from ionic
emulsifiers, nonionic emulsifiers, and combinations thereof. In
some embodiments, the emulsifier is an ionic emulsifier.
[0106] In some embodiments, the ionic emulsifier is selected from
anionic emulsifiers, cationic emulsifiers, and combinations
thereof. In some embodiments, the anionic emulsifiers can be
anionic sulfate emulsifiers, such as, for example, alkyl sulfates
(e.g., ammonium lauryl sulfate, sodium lauryl sulfate (SLS)/sodium
dodecyl sulfate (SDS), and combinations thereof), alkyl ether
sulfates (e.g., sodium laureth sulfate/sodium lauryl ether sulfate,
sodium myreth sulfate, and combinations thereof), and combinations
thereof; anionic sulfonate emulsifiers, such as, for example,
docusates (e.g., dioctyl sodium sulfosuccinate, sulfonate
fluorosurfactants (e.g., perfluorooctanesulfonate and
perfluorobutanesulfonate), alkyl benzene sulfonates, and
combinations thereof); anionic phosphate emulsifiers (e.g., alkyl
aryl ether phosphate, alkyl ether phosphate, and combinations
thereof); anionic carboxylate emulsifiers (e.g., alkyl
carboxylates, (e.g., sodium stearate, sodium lauroyl sarcosinate.
carboxylate fluorosurfactants (e.g., pefluorononanoate,
perfluorooctanoate, and combinations thereof), and combinations
thereof); and combinations thereof. In some embodiments, the
emulsifier is an anionic emulsifier. In one embodiment, the anionic
emulsifier is selected from an anionic sulfate emulsifier, an
anionic sulfonate emulsifier, an anionic phosphate emulsifier, an
anionic carboxylate emulsifier, and combinations thereof. In
another embodiment, an anionic emulsifier is an anionic sulfate
emulsifier. In a still further embodiment, an anionic sulfate
emulsifier is selected from ammonium lauryl sulfate, sodium dodecyl
sulfate, sodium laureth sulfate, sodium lauryl ether sulfate,
sodium myreth sulfate, and combinations thereof. In yet an even
further embodiment, an anionic sulfate emulsifier is sodium dodecyl
sulfate.
[0107] In some embodiments, the cationic emulsifier can be a
pH-dependent primary amine; a pH-dependent secondary amine; a
pH-dependent tertiary amine; octenidine dihydrochloride; a
permanently charged quaternary ammonium cation (e.g.,
alkyltrimethylammonium salts (e.g., cetyl trimethylammonium bromide
(CTAB)/hexadecyl trimethyl ammonium bromide, cetyl
trimethylammonium chloride (CTAC), and combinations thereof),
cetylpyridinium chloride (CPC), benzalkonium chloride (BAC),
benzethonium chloride (BZT), 5-bromo-5-nitro-1,3-dioxane,
dimethyldioctadecylammonium chloride, dioctadecyldimethylammonium
bromide (DODAB), and combinations thereof); and combinations
thereof.
[0108] In some embodiments, the molecular weight of the emulsifier
is selected from 500 g/mole or less, 450 g/mole or less, 400 g/mole
or less, 350 g/mole or less, and 300 g/mole or less. In a further
embodiment, the molecular weight of the emulsifier is selected from
250 g/mole to 500 g/mole, 250 g/mole to 450 g/mole, 250 g/mole to
400 g/mole, 250 g/mole to 350 g/mole, 250 g/mole to 300 g/mole, 300
g/mole to 500 g/mole, 300 g/mole to 450 g/mole, 300 g/mole to 400
g/mole, 300 g/mole to 350 g/mole, 350 g/mole to 500 g/mole, 350
g/mole to 450 g/mole, 350 g/mole to 400 g/mole, 400 g/mole to 500
g/mole, 400 g/mole to 450 g/mole, and 450 g/mole to 500 g/mole. For
example, the molecular weight of SDS is 288 g/mole, and the
molecular weight of CTAB is 364 g/mole. In yet a further
embodiment, the molecular weight of the emulsifier is selected from
250 g/mole to 450 g/mole, 250 g/mole to 400 g/mole, 250 g/mole to
350 g/mole, and 250 g/mole to 300 g/mole.
[0109] In some embodiments, an emulsifier is added as a powder. In
some embodiments, an emulsifier is added in a solution having a
concentration of emulsifier in an amount of 5% to 50%, 5% to 45%,
5% to 40%, 5% to 35%, 5% to 30%, 10% to 50%, 10% to 45%, 10% to
40%, 10% to 35%, 10% to 30%, 15% to 50%, 15% to 45%, 15% to 40%,
15% to 35%, 15% to 30%, 20% to 50%, 20% to 45%, 20% to 40%, 20% to
35%, 20% to 30%, 25% to 50%, 25% to 45%, 25% to 40%, 25% to 35%,
25% to 30%, 30% to 50%, 30% to 45%, 30% to 40%, and 30% to 35%.
[0110] In some embodiments, an emulsifier (e.g., in powder form or
in solution) is added in an amount selected from 0.2% to 10%, 0.2%
to 9.5%, 0.2% to 9%, 0.2% to 8.5%, 0.2% to 8%, 0.2% to 7.5%, 0.2%
to 7%, 0.2% to 6.5%, 0.2% to 6%, 0.2% to 5.5%, 0.2% to 5%, 0.2% to
4.5%, 0.2% to 4%, 0.2% to 3.5%, 0.2% to 3%, 0.2% to 2.5%, 0.2% to
2%, 0.2% to 1.5%, 0.2% to 1%, 0.2% to 0.5%, 0.5% to 10%, 0.5% to
9.5%, 0.5% to 9%, 0.5% to 8.5%, 0.5% to 8%, 0.5% to 7.5%, 0.5% to
7%, 0.5% to 6.5%, 0.5% to 6%, 0.5% to 5.5%, 0.5% to 5%, 0.5% to
4.5%, 0.5% to 4%, 0.5% to 3.5%, 0.5% to 3%, 0.5% to 2.5%, 0.5% to
2%, 0.5% to 1.5%, 0.5% to 1%, 1% to 10%, 1% to 9.5%, 1% to 9%, 1%
to 8.5%, 1% to 8%, 1% to 7.5%, 1% to 7%, 1% to 6.5%, 1% to 6%, 1%
to 5.5%, 1% to 5%, 1% to 4.5%, 1% to 4%, 1% to 3.5%, 1% to 3%, 1%
to 2.5%, 1% to 2%, 1% to 1.5%, 1.5% to 10%, 1.5% to 9.5%, 1.5% to
9%, 1.5% to 8.5%, 1.5% to 8%, 1.5% to 7.5%, 1.5% to 7%, 1.5% to
6.5%, 1.5% to 6%, 1.5% to 5.5%, 1.5% to 5%, 1.5% to 4.5%, 1.5% to
4%, 1.5% to 3.5%, 1.5% to 3%, 1.5% to 2.5%, 1.5% to 2%, 2% to 10%,
2% to 9.5%, 2% to 9%, 2% to 8.5%, 2% to 8%, 2% to 7.5%, 2% to 7%,
2% to 6.5%, 2% to 6%, 2% to 5.5%, 2% to 5%, 2% to 4.5%, 2% to 4%,
2% to 3.5%, 2% to 3%, 2% to 2.5%, 2.5% to 10%, 2.5% to 9.5%, 2.5%
to 9%, 2.5% to 8.5%, 2.5% to 8%, 2.5% to 7.5%, 2.5% to 7%, 2.5% to
6.5%, 2.5% to 6%, 2.5% to 5.5%, 2.5% to 5%, 2.5% to 4.5%, 2.5% to
4%, 2.5% to 3.5%, 2.5% to 3%, 3% to 10%, 3% to 9.5%, 3% to 9%, 3%
to 8.5%, 3% to 8%, 3% to 7.5%, 3% to 7%, 3% to 6.5%, 3% to 6%, 3%
to 5.5%, 3% to 5%, 3% to 4.5%, 3% to 4%, and 3% to 3.5% by weight
(or volume) of the cell broth or oil-containing emulsion. In
another embodiment, an emulsifier (e.g., in powder form or in
solution) is added in an amount selected from 0.2% to 5%, 0.5% to
5%, 1% to 5%, 1.5% to 5%, 2% to 5%, 2.5% to 5%, and 3% to 5% by
weight (or volume) of the cell broth or oil-containing emulsion. In
yet a further embodiment, an emulsifier is added in an amount of
from 0.2% to 10% by weight of the oil-containing emulsion.
[0111] In some embodiments, the emulsifier decreases the
interfacial tension (i.e., surface tension) of the fermentation
broth or lysed cell composition. As used herein, the term
"interfacial tension" or "surface tension" refers to the force
which acts on an imaginary line one meter in length at the
interface between two phases. In some embodiments, the interfacial
tension of the emulsion formed by the emulsifier is lower than an
emulsion formed by the endogenous materials. In some embodiments,
the interfacial tension can be measured in dynes/cm.
[0112] In some embodiments, the emulsifier increases an absolute
value of the zeta potential of the fermentation broth or lysed cell
composition (i.e., increases a positive zeta potential or decreases
a negative zeta potential). In some embodiments, the addition of an
anionic emulsifier can result in a downward shift in the zeta
potential of the cell broth or oil-containing emulsion (e.g.,
decreases a positive zeta potential or increases a negative zeta
potential). In some embodiments, the addition of a cationic
emulsifier can result in an upward shift in zeta potential of the
cell broth or oil-containing emulsion (e.g., increases a positive
zeta potential or increases a negative zeta potential). As used
herein, the term "zeta potential" refers to the electrokinetic
potential between particles in the emulsion. In some embodiments,
the zeta potential can be measured in mV. In some embodiments, the
absolute value of the zeta potential of the emulsion formed by the
emulsifier is higher than an emulsion formed by the endogenous
materials.
[0113] In some embodiments, the addition of an ionic emulsifier
creates an oil-in-water emulsion. In some embodiments, the
oil-in-water emulsion includes, but is not limited to, oil, water,
and an ionic emulsifier.
[0114] In some embodiments, the process further comprises raising
the pH of the coil-containing emulsion. In some embodiments, the pH
is raised by adding a base to the oil-containing emulsion. The
bases that can be used to demulsify the oil-containing emulsion are
the same as those set forth hereinabove. In some embodiments, the
pH is selected from about 7 or above; about 8 or above; about 9 or
above; about 10 or above; about 11 or above; and about 12 or above.
In other embodiments, the pH is selected from a pH of 7 to 13; 7 to
12; 7 to 11; 7 to 10; 7 to 9; 8 to 13; 8 to 12; 8 to 11; 8 to 10; 8
to 9; 9 to 12; 9 to 11; 9 to 10; 10 to 12; and 10 to 11.
[0115] In some embodiments, the process further comprises adding a
salt to the lysed cell composition. The term "salt" refers to an
ionic compound formed by replacing a hydrogen ion from an acid with
a metal (e.g., an alkali metal, an alkali earth metal, and a
transition metal) or a positively charged compound (e.g.,
NH.sub.4.sup.+). In some embodiments, the salt can be an alkali
metal salt, alkali earth metal salts, sulfate salts, or
combinations thereof. Negatively charged ionic species present in a
salt include, but are not limited to, halides, sulfate, bisulfate,
sulfite, phosphate, hydrogen phosphate, dihydrogen phosphate,
carbonate, bicarbonate, and combinations thereof. In some
embodiments, a salt is selected from sodium chloride, sodium
sulfate, sodium carbonate, calcium chloride, potassium sulfate,
magnesium sulfate, monosodium glutamate, ammonium sulfate,
potassium chloride, iron chloride, iron sulfate, aluminum sulfate,
ammonium acetate, and combinations thereof. In some embodiments, a
salt does not include NaOH. A salt can be added as a solid (e.g.,
in crystalline, amorphous, pelletized, and/or granular form),
and/or as a solution (e.g., a dilute solution, a saturated
solution, or a super-saturated solution) containing, for example,
water.
[0116] In some embodiments, the salt is added in an amount of 5 g/l
to 25 g/l, 5 g/l to 10 g/l, 10 g/l to 15 g/l, 15 g/l to 20 g/l, 20
g/l to 25 g/l, or 10 g/l to 20 g/l.
[0117] In other embodiments, a salt is added to the lysed cell
composition in an amount of 20% or less, 15% or less, 10% or less,
7.5% or less, 5% or less, or 2% or less by weight (or volume), of
the lysed cell composition. In some embodiments, a salt is added to
the lysed cell composition in an amount of from about 0.05% to
about 20%, about 0.1% to about 20%, about 0.1% to about 15%, about
0.1% to about 10%, about 0.5% to about 20%, about 0.5% to about
15%, about 0.5% to about 10%, about 0.5% to about 5%, about 0.5% to
about 4%, about 0.5% to about 3%, about 0.5% to about 2.5%, about
0.5% to about 2%, about 0.5% to about 1.5%, about 0.5% to about 1%,
about 1% to about 20%, about 1% to about 15%, about 1% to about
10%, about 1% to about 5%, about 1% to about 4%, 1% to about 3%,
about 1% to about 2.5%, about 1% to about 2%, about 1% to about
1.5%, about 1.5% to about 5%, about 1.5% to about 4%, about 1.5% to
about 3%, about 1.5% to about 2.5%, about 1.5% to about 2%, about
2% to 20%, about 2% to about 15%, about 2% to about 10%, about 2%
to about 5%, about 2% to about 4%, about 2% to about 3%, about 2%
to about 2.5%, about 2.5% to about 5%, about 2.5% to about 4%,
about 2.5% to about 3%, about 3% to about 5%, about 3% to about 4%,
about 4% to about 5%, about 5% to about 20%, about 5% to about 15%,
about 5% to about 10%, about 10% to about 20%, about 10% to about
15%, or about 15% to about 20%, by weight (or volume), cell broth.
For example, when a cell broth weighs 1,000 kg, salt that is added
in an amount of 0.5% to 20%, by weight (or volume), requires the
addition of 5 kg to 200 kg salt. In some embodiments, a salt is
added to the lysed cell composition in an amount of from about
0.05% to about 20%, about 0.1% to about 20% by weight (or volume),
about 0.5% to about 15% by weight (or volume), or about 2% to about
10% by weight (or volume) of the cell broth.
[0118] In some embodiments, the process comprises heating the cells
or the lysed cell composition to at least 10.degree. C., at least
20.degree. C., at least 25.degree. C., at least 30.degree. C., at
least 35.degree. C., at least 40.degree. C., at least 45.degree.
C., at least 50.degree. C., at least 55'' C, at least 60.degree.
C., at least 65.degree. C., at least 70.degree. C., at least
75.degree. C., at least 80.degree. C., at least 85.degree. C., at
least 90.degree. C., at least 95.degree. C., or at least
100.degree. C. In other embodiments, the process comprises heating
the lysed cell composition and/or cells to from about 10.degree. C.
to about 100.degree. C., about 10.degree. C. to about 90.degree.
C., about 10.degree. C. to about 80.degree. C., about 10.degree. C.
to about 70.degree. C., about 20.degree. C. to about 100.degree.
C., about 20.degree. C. to about 90.degree. C., about 20.degree. C.
to about 80.degree. C., about 20.degree. C. to about 70.degree. C.,
about 30.degree. C. to about 100.degree. C., about 30.degree. C. to
about 90.degree. C., about 30.degree. C. to about 80.degree. C.,
about 30.degree. C. to about 70.degree. C., about 40.degree. C. to
about 100.degree. C., about 40.degree. C. to about 90.degree. C.,
about 40.degree. C. to about 80.degree. C., about 50.degree. C. to
about 100.degree. C., about 50.degree. C. to about 90.degree. C.,
about 50.degree. C. to about 80.degree. C., about 50.degree. C. to
about 70.degree. C., about 60.degree. C. to about 100.degree. C.,
about 60.degree. C. to about 90.degree. C., about 60.degree. C. to
about 80.degree. C., about 70.degree. C. to about 100.degree. C.,
about 70.degree. C. to about 90.degree. C., about 80.degree. C. to
about 100.degree. C., about 80.degree. C. to about 90.degree. C.,
or about 90.degree. C. to about 100.degree. C. In further
embodiments, the process comprises heating the cells or the lysed
cell composition from about 70.degree. C. to about 100.degree. C.,
about 70.degree. C. to about 90.degree. C., about 80.degree. C. to
about 100.degree. C., about 80.degree. C. to about 90.degree. C.,
or about 90.degree. C. to about 100.degree. C. In yet further
embodiments, the process comprises heating the cells or the lysed
cell composition to at least 70.degree. C., at least 75.degree. C.,
at least 80.degree. C., at least 85.degree. C., at least 90.degree.
C., at least 95.degree. C., or at least 100.degree. C.
[0119] In some embodiments, cells and/or a lysed cell composition
can be heated in a closed system or in a system with an evaporator.
In some embodiments, cells and/or a lysed cell composition can be
heated in a system with an evaporator such that a portion of the
water present in the cells and/or the lysed cell composition is
removed by evaporation. In some embodiments, the process comprises
heating cells and/or a lysed cell composition in a system with an
evaporator to remove up to 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%,
40%, 45% or 50% by weight (or volume) of water present in the cells
and/or the lysed cell composition. In some embodiments, the process
comprises heating cells and/or a lysed cell composition in a system
with an evaporator to remove 1% to 50%, 1% to 45%, 1% to 40%, 1% to
35%, 1% to 30%, 1% to 25%, 1% to 20%, 1% to 15%, 1% to 10%, 1% to
5%, 5% to 50%, 5% to 45%, 5% to 40%, 5% to 35%, 5% to 30%, 5% to
25%, 5.degree. to 20%, 5% to 15%, 5% to 10%, 10% to 50%, 10% to
45%, 10% to 40%, 10% to 35%, 10% to 30%, 10% to 25%, 10% to 20%,
10% to 15%, 15% to 50%, 15% to 45%, 15% to 40%, 15% to 35%, 15% to
30%, 15% to 25%, 15% to 20%, 20% to 50%, 20% to 45%, 20% to 40%,
20% to 35%, 20% to 30%, 20% to 25%, 25% to 50%, 25% to 45%, 25% to
40%, 25% to 35%, 25% to 30%, 30% to 50%, 30% to 45%, 30% to 40%,
30% to 35%, 35% to 50%, 35% to 45%, 35% to 40%, 40% to 50%, 40% to
45%, or 45% to 50% by weight (or volume) of water.
[0120] The terms "agitating" and "agitation" refer to a process of
affecting motion in the cells and/or the lysed cell composition
through an application of force. In some embodiments, the process
comprises agitating the cells and/or the lysed cell composition by
stirring, mixing, blending, shaking, vibrating, or a combination
thereof.
[0121] In some embodiments, the agitator is a dispersion style
agitator that disperses a base and/or salt in the cells and/or the
lysed cell composition. In some embodiments, the agitator has a
heating plate. In some embodiments, the agitator has a mantle for
stirring. In some embodiments, an agitator has one or more
impellers. As used herein, "impeller" refers to a device arranged
to impart motion to the cells or a lysed cell composition when
rotated. Impellers suitable for use with the present invention
include straight blade impellers, Rushton blade impellers, axial
flow impellers, radial flow impellers, concave blade disc
impellers, high-efficiency impellers, propellers, paddles,
turbines, and combinations thereof.
[0122] In some embodiments, the process of the invention comprises
agitating the cells and/or the lysed cell composition at 0.1
hp/1,000 gal to 10 hp/1,000 gal, 0.5 hp/1,000 gal to 8 hp/1,000
gal, 1 hp/1,000 gal to 6 hp/1,000 gal, or 2 hp/1,000 gal to 5
hp/1,000 gal of composition. In some embodiments, the process
comprises agitating the cells and/or the lysed cell composition at
0.1 hp/1000 gal to 10 hp/1000 gal of composition.
[0123] In some embodiments the invention comprises agitating at 10
rpm or below, 20 rpm or below, 50 rpm below, 100 rpm or below, 150
rpm or below, 200 rpm or below, 250 rpm or below, 300 rpm or below,
350 rpm or below, 400 rpm or below, 10 rpm to 400 rpm, 10 rpm to
350 rpm, 10 rpm to 300 rpm, 10 rpm to 250 rpm, 10 rpm to 200 rpm,
10 rpm to 150 rpm, 10 rpm to 100 rpm, 10 rpm to 50 rpm, 10 rpm to
20 rpm, 20 rpm to 400 rpm, 20 rpm to 350 rpm, 20 rpm to 300 rpm, 20
rpm to 250 rpm, 20 rpm to 200 rpm, 20 rpm to 150 rpm, 20 rpm to 100
rpm, 20 rpm to 50 rpm, 50 rpm to 400 rpm, 50 rpm to 350 rpm, 50 rpm
to 300 rpm, 50 rpm to 250 rpm, 50 rpm to 200 rpm, 50 rpm to 150
rpm, 50 rpm to 100 rpm, 100 rpm to 400 rpm, 100 rpm to 350 rpm, 100
rpm to 300 rpm, 100 rpm to 250 rpm, 100 rpm to 200 rpm, 100 rpm to
150 rpm, 150 rpm to 400 rpm, 150 rpm to 350 rpm, 150 rpm to 300
rpm, 150 rpm to 250 rpm, 150 rpm to 200 rpm, 200 rpm to 400 rpm,
200 rpm to 350 rpm, 200 rpm to 300 rpm, 200 rpm to 250 rpm, 250 rpm
to 400 rpm, 250 rpm to 350 rpm, 250 rpm to 300 rpm, 300 rpm to 400
rpm, 300 rpm to 350 rpm, or 350 rpm to 400 rpm. In some
embodiments, the agitating occurs at a rate of 350 rpm or less.
[0124] In some embodiments, the process includes agitating cells
and/or a lysed cell composition using an agitator having an
impeller tip speed of 90 ft/min to 1,200 ft/min, 200 ft/min to
1,000 ft/min, 300 ft/min to 800 ft/min, 400 ft/min to 700 ft/min,
or 500 ft/min to 600 ft/min. In some embodiments, the process
comprises agitating with an agitator having an impeller tip speed
of 200 ft/min to 1000 ft/min.
[0125] In some embodiments, a process includes agitating cells
and/or a lysed cell composition using an agitator having an
impeller tip speed of 5 cm/sec to 900 cm/sec, 5 cm/sec to 750
cm/sec, 5 cm/sec to 500 cm/sec, 5 cm/sec to 350 cm/sec, 5 cm/sec to
300 cm/sec, 5 cm/sec to 250 cm/sec, 5 cm/sec to 200 cm/sec, 5
cm/sec to 150 cm/sec, 5 cm/sec to 100 cm/sec, 5 cm/sec to 50
cm/sec, 5 cm/sec to 25 cm/sec, 25 cm/sec to 900 cm/sec, 25 cm/sec
to 750 cm/sec, 25 cm/sec to 500 cm/sec, 25 cm/sec to 350 cm/sec, 25
cm/sec to 300 cm/sec, 25 cm/sec to 250 cm/sec, 25 cm/sec to 200
cm/sec, 25 cm/sec to 150 cm/sec, 25 cm/sec to 100 cm/sec, 25 cm/sec
to 50 cm/sec, 50 cm/sec to 900 cm/sec, 50 cm/sec to 750 cm/sec, 50
cm/sec to 500 cm/sec, 50 cm/sec to 350 cm/sec, 50 cm/sec to 300
cm/sec, 50 cm/sec to 250 cm/sec, 50 cm/sec to 200 cm/sec, 50 cm/sec
to 150 cm/sec, 50 cm/sec to 100 cm/sec, 100 cm/sec to 900 cm/sec,
100 cm/sec to 750 cm/sec, 100 cm/sec to 500 cm/sec, 100 cm/sec to
350 cm/sec, 100 cm/sec to 300 cm/sec, 100 cm/sec to 250 cm/sec, 100
cm/sec to 200 cm/sec, 100 cm/sec to 150 cm/sec, 150 cm/sec to 900
cm/sec, 150 cm/sec to 750 cm/sec, 150 cm/sec to 500 cm/sec, 150
cm/sec to 350 cm/sec, 150 cm/sec to 300 cm/sec, 150 cm/sec to 250
cm/sec, 150 cm/sec to 200 cm/sec, 200 cm/sec to 900 cm/sec, 200
cm/sec to 750 cm/sec, 200 cm/sec to 500 cm/sec, 200 cm/sec to 350
cm/sec, 200 cm/sec to 300 cm/sec, 200 cm/sec to 250 cm/sec, 250
cm/sec to 900 cm/sec, 250 cm/sec to 750 cm/sec, 250 cm/sec to 500
cm/sec, 250 cm/sec to 350 cm/sec, 250 cm/sec to 300 cm/sec, 300
cm/sec to 900 cm/sec, 300 cm/sec to 750 cm/sec, 300 cm/sec to 500
cm/sec, 300 cm/sec to 350 cm/sec, 350 cm/sec to 900 cm/sec, 350
cm/sec to 850 cm/sec, 350 cm/sec to 800 cm/sec, 350 cm/sec to 750
cm/sec, 350 cm/sec to 700 cm/sec, 350 cm/sec to 650 cm/sec, 350
cm/sec to 600 cm/sec, 350 cm/sec to 550 cm/sec, 350 cm/sec to 500
cm/sec, 350 cm/sec to 450 cm/sec, 350 cm/sec to 400 cm/sec, 400
cm/sec to 900 cm/sec, 400 cm/sec to 850 cm/sec, 400 cm/sec to 800
cm/sec, 400 cm/sec to 750 cm/sec, 400 cm/sec to 700 cm/sec, 400
cm/sec to 650 cm/sec, 400 cm/sec to 600 cm/sec, 400 cm/sec to 550
cm/sec, 400 cm/sec to 500 cm/sec, 400 cm/sec to 450 cm/sec, 450
cm/sec to 900 cm/sec, 450 cm/sec to 850 cm/sec, 450 cm/sec to 800
cm/sec, 450 cm/sec to 750 cm/sec, 450 cm/sec to 700 cm/sec, 450
cm/sec to 650 cm/sec, 450 cm/sec to 600 cm/sec, 450 cm/sec to 550
cm/sec, 450 cm/sec to 500 cm/sec, 500 cm/sec to 900 cm/sec, 500
cm/sec to 850 cm/sec, 500 cm/sec to 800 cm/sec, 500 cm/sec to 750
cm/sec, 500 cm/sec to 700 cm/sec, 500 cm/sec to 650 cm/sec, 500
cm/sec to 600 cm/sec, 500 cm/sec to 550 cm/sec, 550 cm/sec to 900
cm/sec, 550 cm/sec to 850 cm/sec, 550 cm/sec to 800 cm/sec, 550
cm/sec to 750 cm/sec, 550 cm/sec to 700 cm/sec, 550 cm/sec to 650
cm/sec, 550 cm/sec to 600 cm/sec, 600 cm/sec to 900 cm/sec, 600
cm/sec to 850 cm/sec, 600 cm/sec to 800 cm/sec, 600 cm/sec to 750
cm/sec, 600 cm/sec to 700 cm/sec, 600 cm/sec to 650 cm/sec, 650
cm/sec to 900 cm/sec, 650 cm/sec to 850 cm/sec, 650 cm/sec to 800
cm/sec, 650 cm/sec to 750 cm/sec, 650 cm/sec to 700 cm/sec, 700
cm/sec to 900 cm/sec, 700 cm/sec to 850 cm/sec, 700 cm/sec to 800
cm/sec, 700 cm/sec to 750 cm/sec, 750 cm/sec to 900 cm/sec, 750
cm/sec to 850 cm/sec, 750 cm/sec to 800 cm/sec, 800 cm/sec to 900
cm/sec, 800 cm/sec to 850 cm/sec, or 850 cm/sec to 900 cm/sec. The
term "impeller tip speed" refers to the speed of the outer most
portion of the impeller as it rotates around its central axis.
[0126] In some embodiments, the agitating (and optional additional
steps as described herein) is performed in a container comprising
an impeller, wherein a ratio of the impeller diameter to the
container volume is 0.1 to 0.5, 0.1 to 0.4, 0.2 to 0.5, 0.2 to 0.4,
0.3 to 0.5, or 0.3 to 0.4.
[0127] In some embodiments, the agitating (and optional additional
steps as described herein) is performed in a container comprising
an impeller, wherein a ratio of the impeller diameter to the inner
diameter of the container is at least 0.25, at least 0.34, at least
0.65, 0.25 to 0.65, 0.25 to 0.33, 0.3 to 0.6, 0.3 to 0.5, 0.3 to
0.4, 0.34 to 0.65, 0.34 to 0.6, 0.34 to 0.55, 0.37 to 0.55, 0.4 to
0.65, 0.4 to 0.6, 0.4 to 0.5, or 0.42 to 0.55.
[0128] In some embodiments, agitating comprises mixing cells and/or
a lysed cell composition such that the cells and/or the lysed cell
composition is placed under flow conditions described by a Reynolds
number of 10 to 10,000, 1,000 to 10,000, 1,500 to 10,000, or 2,000
to 10,000. In some embodiments, a lysed cell emulsion during the
agitating has a Reynolds number of 2,000 or more, 3,000 or more, or
5,000 or more, or 2,000 to 10,000, 3,000 to 10,000, or 5,000 to
10,000.
[0129] In some embodiments, the agitation vessels can have two
impellers. In some embodiments, the impellers are Rushton blade
impellers. In some embodiments, the impellers are separated from
each other by a distance at least equal to a diameter of the
smallest impeller. In some embodiments, the impellers are 30 inches
to 40 inches, 33 inches to 37 inches, 33 inches, 34 inches, 35
inches, 36 inches or 37 inches from tip to tip. In some
embodiments, the agitation vessels have a volume of at least 10,000
liters, at least 20,000 liters, at least 30,000 liters, at least
40,000 liters or at least 50,000 liters. In some embodiments, the
agitation vessels have an inner diameter of 90 inches to 110
inches, 95 inches to 105 inches, 98 inches, 99 inches, 100 inches,
101 inches, or 102 inches. In some embodiments, a first impeller is
located 15 inches to 20 inches, 16 inches to 19 inches, or 17
inches to 18 inches from a bottom of the agitation vessel and a
second impeller is located 60 inches to 80 inches, 65 inches to 75
inches, 68 inches, 69 inches, 70 inches, 71 inches, 72 inches, 73
inches, 74 inches, or 75 inches above the first impeller. In some
embodiments, a lysed cell composition is agitated at least 50 rpm,
at least 60 rpm, or at least 70 rpm. In some embodiments, a lysed
cell composition is agitated at 50 rpm to 70 rpm, 50 rpm to 60 rpm,
or 60 rpm to 70 rpm.
[0130] In some embodiments, the process further comprises agitating
the cells or lysed cell composition.
[0131] In some embodiments, the process comprises demulsifying an
oil-containing emulsion and then separating the oil from the
emulsion.
[0132] In an alternative embodiment, the number of times the lysed
cell composition is washed can be decreased by 1 time, 2 times, 3
times or more. In some embodiments, the washing is no more than 1
time, 2 times, or 3 times.
[0133] In some embodiments, the process can occur in a single
vessel. In some embodiments, the single vessel includes a
fermentation vessel. In some embodiments, the fermentation vessel
can have a volume of at least 20,000 liters, at least 50,000
liters, at least 100,000 liters, at least 120,000 liters, at least
150,000 liters, at least 200,000 liters, or at least 220,000
liters. In some embodiments, the fermentation vessel can have a
volume of 20,000 liters to 220,000 liters, 20,000 liters to 100,000
liters, 20,000 liters to 50,000 liters, 50,000 liters to 220,000
liters, 50,000 liters to 150,000 liters, 50,000 liters to 100,000
liters, 100,000 liters to 220,000 liters, 100,000 liters to 150,000
liters, 100,000 liters to 120,000 liters, 150,000 liters to 220,000
liters, 150,000 liters to 200,000 liters, or 200,000 liters to
220,000 liters.
[0134] In some embodiments, a quantity of cells or a lysed cell
composition formed in a vessel can be transferred into one or more
agitation vessels. In some embodiments, the agitation vessels can
have a volume of at least 20,000 liters, at least 30,000 liters, at
least 40,000 liters or at least 50,000 liters. In some embodiments,
the agitation vessels can have a volume of 20,000 liters to 50,000
liters, 20,000 liters to 40,000 liters, 20,000 liters to 30,000
liters, 30,000 liters to 50,000 liters, 30,000 liters to 40,000
liters or 40,000 liters to 50,000 liters.
[0135] In general, the processes described herein do not utilize an
organic solvent to obtain, separate, or otherwise recover a
microbial oil from the microbial cells. In some embodiments, no
organic solvent is used in obtaining microbial oil from microbial
cells. In another embodiment, an organic solvent is not added to
cells, is not added to a lysed cell composition, and/or is not
added to an oil during the processes disclosed herein in an amount
or concentration sufficient to obtain a microbial oil. Organic
solvents include polar solvents, non-polar solvents, water-miscible
solvents, water-immiscible solvents, and combinations thereof.
[0136] In some embodiments, the process further comprises
separating an oil-containing emulsion from a lysed cell
composition. In some embodiments, the process comprises separating
an oil-containing emulsion from a lysed cell composition by heating
the lysed cell composition. In some embodiments, an oil is
separated from a demulsified lysed cell composition by centrifuging
the lysed cell composition. In some embodiments, the separating
comprises centrifuging at a temperature of 10.degree. C. to
100.degree. C. In some embodiments, the oil-containing emulsion is
separated from the lysed cell composition by first raising the pH
(e.g. by adding a base that is described hereinabove) and then
centrifuging the oil-containing emulsion and the lysed cell
composition to obtain the oil-containing emulsion.
[0137] In some embodiments, the process comprises separating an
oil-containing emulsion from the lysed cell composition by
centrifuging the oil-containing emulsion and the lysed cell
composition at a temperature of at least 10.degree. C., at least
20.degree. C., at least 25.degree. C., at least 30.degree. C., at
least 35.degree. C., at least 40.degree. C., at least 45.degree.
C., at least 50.degree. C., at least 55.degree. C., at least
60.degree. C., at least 65.degree. C., at least 70.degree. C., at
least 75.degree. C., at least 80.degree. C., at least 85.degree.
C., at least 90.degree. C., at least 95.degree. C., or at least
100.degree. C. In some embodiments, the process comprises
separating an oil-containing emulsion from the lysed cell
composition by centrifuging the oil-containing emulsion and lysed
cell composition at a temperature of 10.degree. C. to 100.degree.
C., 10.degree. C. to 90.degree. C., 10.degree. C. to 80.degree. C.,
20.degree. C. to 100.degree. C., 20.degree. C. to 90.degree. C.,
20.degree. C. to 80.degree. C., 25.degree. C. to 100.degree. C.,
25.degree. C. to 90.degree. C., 25.degree. C. to 80.degree. C.,
25.degree. C. to 75.degree. C., 30.degree. C. to 100.degree. C.,
30.degree. C. to 90.degree. C., 30.degree. C. to 80.degree. C.,
40.degree. C. to 100.degree. C., 40.degree. C. to 90.degree. C.,
40.degree. C. to 80.degree. C., 50.degree. C. to 100.degree. C.,
50.degree. C. to 90.degree. C., 50.degree. C. to 80.degree. C.,
50.degree. C. to 70.degree. C., 60.degree. C. to 100.degree. C.,
60.degree. C. to 90.degree. C., 60.degree. C. to 80.degree. C.,
60.degree. C. to 70.degree. C., 70.degree. C. to 100.degree. C.,
70.degree. C. to 90.degree. C., 70.degree. C. to 80.degree. C.,
80.degree. C. to 100.degree. C., 80.degree. C. to 90.degree. C., or
90.degree. C. to 100.degree. C.
[0138] In some embodiments, centrifuging is conducted at a feed
rate (of the lysed cell composition into a centrifuge) of 1
kilogram per minute (kg/min) to 500 kg/min, 1 kg/min to 400 kg/min,
1 kg/min to 300 kg/min, 1 kg/min to 200 kg/min, 1 kg/min to 100
kg/min, 1 kg/min to 75 kg/min, 1 kg/min to 50 kg/min, 1 kg/min to
40 kg/min, 1 kg/min to 30 kg/min, 1 kg/min to 25 kg/min, 1 kg/min
to 10 kg/min, 10 kg/min to 500 kg/min, 10 kg/min to 400 kg/min, 10
kg/min to 300 kg/min, 10 kg/min to 200 kg/min, 10 kg/min to 100
kg/min, 10 kg/min to 75 kg/min, 10 kg/min to 50 kg/min, 10 kg/min
to 40 kg/min, 10 kg/min to 30 kg/min, 20 kg/min to 500 kg/min, 20
kg/min to 400 kg/min, 20 kg/min to 300 kg/min, 20 kg/min to 200
kg/min, 20 kg/min to 100 kg/min, 20 kg/min to 75 kg/min, 20 kg/min
to 50 kg/min, 20 kg/min to 40 kg/min, 25 kg/min to 500 kg/min, 25
kg/min to 400 kg/min, 25 kg/min to 300 kg/min, 25 kg/min to 200
kg/min, 25 kg/min to 100 kg/min, 25 kg/min to 75 kg/min, 25 kg/min
to 50 kg/min, 30 kg/min to 60 kg/min, 30 kg/min to 50 kg/min, 30
kg/min to 40 kg/min, 50 kg/min to 500 kg/min, 100 kg/min to 500
kg/min, or 200 kg/min to 500 kg/min.
[0139] In some embodiments, the process comprises centrifuging the
lysed cell composition at a centrifugal force of 1,000 g to 25,000
g, 1,000 g to 20,000 g, 1,000 g to 10,000 g, 2,000 g to 25,000 g,
2,000 g to 20,000 g, 2,000 g to 15,000 g, 3,000 g to 25,000 g,
3,000 g to 20,000 g, 5,000 g to 25,000 g, 5,000 g to 20,000 g,
5,000 g to 15,000 g, 5,000 g to 10,000 g, 5,000 g to 8,000 g,
10,000 g to 25,000 g, 15,000 g to 25,000 g, or at least 1,000 g, at
least 2,000, g, at least 4,000 g, at least 5,000 g, at least 7,000
g, at least 8,000 g, at least 10,000 g, at least 15,000 g, at least
20,000 g, or at least 25,000 g. As used herein, "g" refers to
standard gravity or approximately 9.8 m/s.sup.2. In some
embodiments, the process comprises centrifuging a demulsified lysed
cell composition at 4,000 rpm to 14,000 rpm, 4,000 rpm to 10,000
rpm, 6,000 rpm to 14,000 rpm, 6,000 rpm to 12,000 rpm, 8,000 to
14,000 rpm, 8,000 rpm to 12,000 rpm, or 8,000 rpm to 10,000
rpm.
[0140] In some embodiments, the oil can be recovered, for example,
by decanting, skimming, vacuuming, pumping, sucking off, drawing
off, siphoning, or otherwise recovering the microbial oil from the
surface of the separated composition.
[0141] In some embodiments, the process comprises drying the oil
that has been recovered to remove water from the oil. In some
embodiments, drying the oil can include, but is not limited to,
heating the oil to evaporate water. In some embodiments, after
drying, the oil has a water content by weight (or volume)
percentage of oil that is less than 3%, less than 2.5%, less than
2%, less than 1.5%, less than 1%, less than 0.5% less than 0.1%, or
0%. In some embodiments, after drying, the oil has a water content
by weight (or volume) percentage of oil of 0% to 3%, 0% to 2.5%, 0%
to 2%, 0% to 1.5%, 0% to 1%, 0% to 0.5%, 0.1% to 3%, 0.1% to 2.5%,
0.1% to 2%, 0.1% to 1.5%, 0.1% to 1%, 0.1% to 0.5%, 0.5% to 3%,
0.5% to 2.5%, 0.5% to 2%, 0.5% to 1.5%, 0.5% to 1%, 1% to 3%, 1% to
2.5%, 1% to 2%, 1% to 1.5%, 1.5% to 3%, 1.5% to 2.5%, 1.5% to 2%,
2% to 3%, 2% to 2.5%, or 2.5% to 3%.
[0142] Disclosed herein is a microbial oil that can be obtained
from microbial cells by any of the processes disclosed herein. In
some embodiments, the oil comprises at least 30% by weight (or
volume) arachidonic acid. In some embodiments, the oil comprises at
least 30% by weight (or volume) docoeahoxaenoic acid.
[0143] The Anisidine value (AV) is determined in accordance with
AOCS Official Method Cd 18-90. In one embodiment, the oil described
herein has an AV of less than about 50; less than about 40; less
than about 30; less than about 20; less than about 15; or less than
about 10. In some embodiments, the oil has an AV of less than about
50. The term anisidine value refers to the measure of secondary
reaction products, such as aldehydes and ketones that occur during
oxidation of the oil.
[0144] The peroxide value (PV) is determined in accordance with the
AOCS Official Method Cd 8-53. In one embodiment, the oil described
herein has a PV less than about 20 meq/kg; less than about 10
meg/kg; or less than about 5 meg/kg. In some embodiments, the oil
has a PV of less than about 5 meg/kg. The term peroxide value
refers to the measure of primary reaction products, such as
peroxides and hydroperoxides, that occur during oxidation of the
oil. As used herein peroxide value is measured in meq/kg.
[0145] In some embodiments, the oil has a phosphorus content of 100
ppm or less, 95 ppm or less, 90 ppm or less, 85 ppm or less, 80 ppm
or less, 75 ppm or less, 70 ppm or less, 65 ppm or less, 60 ppm or
less, 55 ppm or less, 50 ppm or less, 45 ppm or less, 40 ppm or
less, 35 ppm or less, 30 ppm or less, 25 ppm or less, 20 ppm or
less, 15 ppm or less, 10 ppm or less, 9 ppm or less, 8 ppm or less,
7 ppm or less, 6 ppm or less, 5 ppm or less, 4 ppm or less, 3 ppm
or less, 2 ppm or less, or 1 ppm or less. In some embodiments, the
oil has a phosphorus content of about 8 ppm or less.
[0146] In some embodiments, the oil comprises one or more PUFAs. In
some embodiments, the oil comprises at least 10%, at least 15%, at
least 20%, at least 25%, at least 30%, at least 35%, at least 40%,
at least 45%, at least 50%, at least 60%, at least 70% or at least
80% PUFA (by PUFA weight). In some embodiments, the oil comprises
at least 10%, at least 15%, at least 20%, at least 25%, at least
30%, at least 35%, at least 40%, at least 45%, at least 50%, at
least 60%, at least 70% or at least 80% DHA (by DHA weight), and/or
at least 10%, at least 15%, or at least 20% DPA n-6 (by DPA n-6
weight), and/or at least 10%, at least 15%, or at least 20% EPA (by
EPA weight), and/or at least 10%, at least 15%, at least 20%, at
least 25%, at least 30%, at least 35%, at least 40%, at least 45%,
at least 50%, at least 55%, at least 60%, at least 65%, at least
70%, at least 75%, or at least 80% ARA (by ARA weight). In some
embodiments, an oil comprises less than 50%, less than 40%, less
than 30%, less than 20%, less than 15%, less than 10%, or less than
5% EPA (by EPA weight). In some embodiments, an oil comprises less
than 50%, less than 40%, less than 30%, less than 20%, less than
15%, less than 10%, or less than 5% DHA (by DHA weight). In some
embodiments, an oil comprises less than 10%, less than 5%, less
than 2%, less than 1%, or less than 0.5% by weight (or volume)
sterols.
[0147] In some embodiments, an oil comprises at least 50%, at least
60%, at least 70%, at least 80%, at least 90%, at least 95%, or 50%
to 95%, 50% to 90%, 50% to 85%, 50% to 80%, 50% to 75%, 60% to 95%,
60% to 90%, 60% to 85%, 70% to 95%, 70% to 90%, 70% to 85%, 75% to
95%, 75% to 90%, or 75% to 85%, by weight (or volume) of
triglycerides.
[0148] In some embodiments, the triglycerides comprise at least
10%, at least 20%, at least 30%, at least 35%, at least 40%, at
least 50%, at least 60%, at least 70% or at least 80% by weight (or
volume) DHA. In some embodiments, the triglycerides comprise at
least 10%, at least 20%, at least 30%, at least 35%, at least 40%,
at least 45%, at least 50%, at least 55%, at least 60%, at least
65%, at least 70%, at least 75%, or at least 80% by weight (or
volume) ARA. In some embodiments, the triglycerides comprise at
least 50%, at least 40%, at least 30%, at least 20%, at least 15%,
at least 10%, or at least 5% by weight (or volume) EPA.
[0149] In one embodiment, the microbial oil obtained and/or
recovered by any of the processes described herein is a crude oil.
In another embodiment, the oil described herein is a refined oil. A
"crude oil" is an oil obtained from microbial cells without further
processing. A "refined oil" is an oil obtained by treating a crude
oil with standard processing of refining, bleaching, and/or
deodorizing. See, e.g., U.S. Pat. No. 5,130,242. In some
embodiments, refining includes, but is not limited to, base
refining, degumming, acid treatment, alkali treatment, cooling,
heating, bleaching, deodorizing, deacidification, and combinations
thereof.
[0150] In some embodiments, the process comprises concentrating a
fermentation broth comprising microbial cells. In some embodiments,
the process comprises concentrating the lysed cell composition. As
used herein, "concentrating" refers to removing water from a
composition. Concentrating can include, but is not limited to,
evaporating, chemical drying, centrifuging, and the like, and
combinations thereof. In some embodiments, a cell composition or a
lysed cell composition is concentrated to provide an oil
concentration of at least 4%, at least 5%, at least 10%, at least
15%, at least 20%, at least 25%, or at least 30% by weight (or
volume) of the composition. In some embodiments, a cell composition
or a lysed cell composition is concentrated to provide an oil
concentration of 4% to 40%, 4% to 30%, 4% to 20%, 4% to 15%, 5% to
40%, 5% to 30%, 5% to 20%, 10% to 40%, 10% to 30%, 10% to 20%, 15%
to 40%, 15% to 30%, 20% to 40%, 20% to 30%, 25% to 40%, or 30% to
40% by weight (or volume) of the composition.
[0151] Effective culture conditions for a microbial cell for use
with the invention include, but are not limited to, effective
media, bioreactor, temperature, pH, and oxygen conditions that
permit oil production. An effective medium refers to any medium in
which a microbial cell, e.g., Thraustochytriales microbial cell, is
typically cultured. Such media typically comprises an aqueous
medium having assimilable carbon, nitrogen, and phosphate sources,
as well as appropriate salts, minerals, metals, and other
nutrients, such as vitamins. Microbial cells for use with the
present invention can be cultured in conventional fermentation
bioreactors, shake flasks, test tubes, microtiter dishes, and petri
plates.
[0152] In some embodiments, a microbial cell comprises at least 30%
by weight (or volume) oil, at least 35% by weight (or volume) oil,
at least 40% by weight (or volume) oil, at least 50% by weight (or
volume) oil, at least 60% by weight (or volume) oil, at least 70%
by weight (or volume) oil, or at least 80% by weight (or volume)
oil. In some embodiments, a microbial cell for use with the present
invention is capable of producing at least 0.1 grams per liter per
hour (g/L/h) of DHA, at least 0.2 g/L/h of DHA, at least 0.3 g/L/h
of DHA, or at least 0.4 g/L/h of DHA. In some embodiments, a
microbial cell for use with the present invention is capable of
producing at least 0.01 grams per liter per hour (g/L/h) of ARA, at
least 0.05 g/L/h of ARA, at least 0.1 g/L/h of ARA, at least 0.2
g/L/h of ARA, at least 0.3 g/L/h of ARA, or at least 0.4 g/L/h of
ARA.
[0153] In some embodiments, an oil obtained according to any of the
processes described herein, the spent biomass, or combinations
thereof can be used directly as a food or food ingredient, such as
an ingredient in baby food, infant formula, beverages, sauces,
dairy based foods (such as milk, yogurt, cheese and ice-cream),
oils (e.g., cooking oils or salad dressings), and baked goods;
nutritional supplements (e.g., in capsule or tablet forms); feed or
feed supplement for any non-human animal (e.g., whose products
(e.g., meat, milk, or eggs) are consumed by humans); food
supplements; and pharmaceuticals (in direct or adjunct therapy
application). The term "animal" refers to any organism belonging to
the kingdom Animalia and includes any human animal, and non-human
animal from which products (e.g., milk, eggs, poultry meat, beef,
pork or lamb) are derived. In some embodiments, the oil and/or
biomass can be used in seafood. Seafood is derived from, without
limitation, fish, shrimp and shellfish. The term "products"
includes any product derived from such animals, including, without
limitation, meat, eggs, milk or other products. When the oil and/or
biomass is fed to such animals, polyunsaturated oils can be
incorporated into the flesh, milk, eggs or other products of such
animals to increase their content of these oils.
EXAMPLES
[0154] As used herein, the "extraction yield" is the amount, by
weight, of lipid in the oil-containing emulsion expressed as a
percentage of the amount, by weight, of lipid in the cell broth.
The "refining yield" is the amount, by weight, of lipid in the
refined oil expressed as a percentage of the amount, by weight, of
lipid in the oil-containing emulsion. The "total yield" is the
amount, by weight, of lipid in the refined oil expressed as a
percentage of the amount, by weight, of lipid in the cell
broth.
Example 1
[0155] An unwashed cell broth (75.9 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on the
weight of the cell broth, agitated at a speed of 184 RPM, heated to
60.degree. C. and held for 2 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to
10.5 by adding 6N NaOH. NaCl in an amount of 2% by weight of the
cell broth was added and heated to 90.degree. f and held for 19
hours. The pH of the lysed cell composition was adjusted to 8.2 by
adding 6N NaOH, agitated at 150 RPM, and held for 4.5 hours. The pH
of the lysed cell composition was adjusted to 8.3 by adding 6N
NaOH, agitated at 150 RPM, and held for 1 hour. An oil-containing
emulsion was formed and separated from the lysed cell composition
by heating the oil-containing emulsion and lysed cell composition
to 80.degree. C. and then centrifuging (Alfa Laval Disc Stack
Centrifuge, LAPX 404/Clara 20). The extraction yield was 87.2%. The
recovered oil-containing emulsion had an AV of 12.3 and contained
1.24% free fatty acids. The oil-containing emulsion was placed in a
20 L tank with nitrogen blanketing and was heated to 50-55.degree.
C. and 50% citric acid was added in an amount of 0.2% by weight of
the emulsion and held for 15 minutes. The oil-containing emulsion
was further heated to 60-65.degree. C. and NaOH was added in an
amount of 12.5% by weight of the free fatty acid composition and
weight of the oil-containing emulsion, and held for 30 minutes to
refine the emulsion. The oil was separated from the emulsion by
centrifuging. The refining yield was 86.2%. The total yield was
75%. The refined oil had an AV of 10.
TABLE-US-00001 TABLE 1 Comparison of oil-containing emulsion and
refined oil Emulsion Refined oil Moisture 17.5% 0.1% Fat 80.5%
98.1%
Example 2
[0156] An unwashed cell broth (78.3 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the tell broth, agitated at a speed of 184 RPM, heated to
60.degree. C. and held for 2 hours with pH controlled at 7.5 with
6N NaOH. While maintaining the agitation, the pH of the lysed cell
composition was adjusted to 9.7 by adding 6N NaOH. NaCl in an
amount of 2% by weight of the cell broth was added and heated to
90.degree. C. and held for 18 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to 8.3
by adding 6N NaOH and held for 4.5 hours. An oil-containing
emulsion was formed and separated from the lysed cell composition
by heating the oil-containing emulsion and lysed cell composition
to 80.degree. C. and then centrifuging (Alfa Laval Disc Stack
Centrifuge, LAPX 404/Clara 20). The extraction yield was 86.3%. The
oil-containing emulsion had an AV of 12.9 and contained 1.02% free
fatty acids. The oil-containing emulsion was placed in a 20 L tank
with nitrogen blanketing and was heated to 50-55.degree. C. and 50%
citric acid was added in an amount of 0.2% by weight of the
emulsion and held for 15 minutes. The oil-containing emulsion was
further heated to 60-65.degree. C. and NaOH was added in an amount
of 12.5% by weight of the free fatty acid composition and weight of
the oil-containing emulsion, and held for 30 minutes to refine the
emulsion. The oil was separated from the emulsion by centrifuging.
The refining yield was 98.9%. The total yield was 85.3%. The
recovered oil had an AV of 13.5 and contained 0.5% free fatty
acids.
Example 3
[0157] An unwashed cell broth (86.5 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 185 RPM, heated to
60.degree. C. and held for 2 hours with pH controlled at 7.5 with
6N NaOH. While maintaining the agitation, the pH of the lysed cell
composition was adjusted to 9.9 by adding 6N NaOH. NaCl in an
amount of 2% by weight of the cell broth was added and heated to
90.degree. C. and held for 18 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to 8.5
by adding 6N NaOH and held for 4 hours. An oil-containing emulsion
was formed and separated from the lysed cell composition by heating
the oil-containing emulsion and lysed cell composition to
80.degree. C. and then centrifuging (Alfa Laval Disc Stack
Centrifuge, LAPX 404/Clara 20). The extraction yield was 94.4%. The
oil-containing emulsion had an AV of 4.5 and contained 1.88% free
fatty acids. The oil-containing emulsion was placed in a 20 L tank
with nitrogen blanketing and was heated to 50-55.degree. C. and 50%
citric acid was added in an amount of 0.2% by weight emulsion and
held for 15 minutes. The oil-containing emulsion was further heated
to 60-65.degree. C. and NaOH was added in an amount of 12.5% by
weight of the free fatty acid composition and weight of the
oil-containing emulsion, and held for 30 minutes to refine the
emulsion. The oil was separated from the emulsion by centrifuging.
The refining yield was 91.5%. The total yield was 86.4%. The
refined oil had an AV of 13.5 and contained 0.5% free fatty
acids.
Example 4
[0158] An unwashed cell broth (82.6 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 185 RPM, heated to
60.degree. C. and held for 2 hours with pH controlled at 7.5 with
6N NaOH. While maintaining the agitation, the pH of the lysed cell
composition was adjusted to 10.2 by adding 6N NaOH. NaCl in an
amount of 2% by weight of the cell broth was added and heated to
90.degree. C. and held for 4 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to 8.3
by adding 6N NaOH and held for 11 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to 7.8
by adding 6N NaOH and held for 7 hours. An oil-containing emulsion
was formed and separated from the lysed cell composition by heating
the oil-containing emulsion and lysed cell composition to
80.degree. C. and then centrifuging (Alfa Laval Disc Stack
Centrifuge, LAPX 404/Clara 20). The extraction yield was 99.3%. The
oil-containing emulsion had an AV of 4. and contained 0.67% free
fatty acids. The oil-containing emulsion was placed in a 20 L tank
with nitrogen blanketing and was heated to 50-55.degree. C. and 50%
citric acid was added in an amount of 0.2% by weight of the
emulsion and held for 15 minutes. The oil-containing emulsion was
further heated to 60-65.degree. C. and NaOH was added in an amount
of 12.5% by weight of the free fatty acid composition and weight of
the oil-containing emulsion, and held for 30 minutes to refine the
emulsion. The oil was separated from the emulsion by centrifuging.
The refining yield was 92.7%. The total yield was 92.3%. The
refined oil had an AV of 2.8 and contained 0.54% free fatty
acids.
Example 5
[0159] An unwashed cell broth (88.5 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 183 RPM, heated to
60.degree. C. and held for 2 hours with pH controlled at 7.5 with
6N NaOH. While maintaining the agitation, the pH of the lysed cell
composition was adjusted to 10.2 by adding 6N NaOH. NaCl in an
amount of 2% by weight of the cell broth was added and heated to
90.degree. C. and held for 22 hours. An oil-containing emulsion was
formed and separated from the lysed cell composition by heating the
oil-containing emulsion and lysed tell composition to 80.degree. C.
and then centrifuging (Alfa Laval Disc Stack Centrifuge, LAPX
404/Clara 20). The extraction yield was 94%. The oil-containing
emulsion contained 2.1% free fatty acids. The oil-containing
emulsion was placed in a 20 L tank with nitrogen blanketing and was
heated to 50-55.degree. C. and 50% citric acid was added in an
amount of 0.2% by weight of the emulsion and held for 15 minutes.
The oil-containing emulsion was further heated to 60-65.degree. C.
and NaOH was added in an amount of 12.5% by weight of the free
fatty acid composition and weight of the oil-containing emulsion,
and held for 30 minutes to refine the emulsion. The oil was
separated from the emulsion by centrifuging. The refining yield was
94.3%. The total yield was 87%. The refined oil contained 0.62%
free fatty acids.
Example 6
[0160] An unwashed cell broth (84.9 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 184 RPM, heated to
60.degree. C. and held for 2 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to
10.5 by adding 6N NaOH. NaCl in an amount of 2% by weight of the
cell broth was added and heated to 90.degree. C. and held for 22
hours. An oil-containing emulsion was formed and separated from the
lysed cell composition by heating the oil-containing emulsion and
lysed cell composition to 80.degree. C. and then centrifuging (Alfa
Laval Disc Stack Centrifuge, LAPX 404/Clara 20). The extraction
yield was 93.9%. The oil-containing emulsion contained 1.5% free
fatty acids. The oil-containing emulsion was placed in a 20 L tank
with nitrogen blanketing and was heated to 50-55.degree. C. and 50%
citric acid was added in an amount of 0.2% by weight of the
emulsion and held for 15 minutes. The oil-containing emulsion was
further heated to 60-65.degree. C. and NaOH was added in an amount
of 12.5% by weight of the free fatty acid composition and weight of
the oil-containing emulsion, and held for 30 minutes to refine the
emulsion. The oil was separated from the emulsion by centrifuging.
The refining yield was 89.8%. The total yield was 84.3%.
TABLE-US-00002 TABLE 2 Comparison of oil-containing emulsion and
refined oil Emulsion Refined oil Moisture 24.8% 1% Fat 71.2%
95.8%
Example 7
[0161] An unwashed cell broth (77.2 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were mechanically lysed. 6N NaOH was added to the lysed
cell composition to pH adjust the composition to 9.5, NaCl in an
amount of 2% by weight of the cell broth was added, agitated at 184
RPM, heated to 90.degree. C. and held for 25 hours. An
oil-containing emulsion was formed and separated from the lysed
cell composition by heating the oil-containing emulsion and lysed
cell composition to 80.degree. C. and then centrifuging (Alfa Laval
Disc Stack Centrifuge, LAPX 404/Clara 20). The extraction yield was
91.1%. The oil-containing emulsion contained 1.7% free fatty acids.
The oil-containing emulsion was heated to 50-55.degree. C. and held
for 8 hours and 15 minutes. The oil was separated from the emulsion
by centrifuging. The refining yield was 83.7%. The total yield was
76.2%.
Example 8
[0162] An unwashed cell broth (74.8 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 184 RPM, heated to
60.degree. C. and held for 2 hours. While maintaining the
agitation, the pH of the lysed cell composition was adjusted to
10.5 by adding 6N NaOH. NaCl in an amount of 2% by weight of the
cell broth was added and heated to 90.degree. C. and held for 23
hours. An oil-containing emulsion was formed and separated from the
lysed cell composition by heating the oil-containing emulsion and
lysed cell composition to 80.degree. C. and then centrifuging (Alfa
Laval Disc Stack Centrifuge, LAPX 404/Clara 20). The extraction
yield was 82.8%. The oil-containing emulsion contained 1.1% free
fatty acids. The oil-containing emulsion was placed in a 20 L tank
with nitrogen blanketing and was heated to 50-55.degree. C. and 50%
citric acid was added in an amount of 0.2% by weight of the
emulsion and held for 15 minutes. The oil-containing emulsion was
further heated to 60-65.degree. C. and NaOH was added in an amount
of 12.5% by weight of the free fatty acid composition and weight of
the oil-containing emulsion, and held for 30 minutes to refine the
emulsion. The oil was separated from the emulsion by centrifuging.
The refining yield was 94.9%. The total yield was 78.5%.
Example 9
[0163] An unwashed cell broth (83.7 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) in an amount of 0.5% based on weight of the
cell broth, agitated at a speed of 184 RPM, heated to 60.degree. C.
and held for 2 hours. While maintaining the agitation, the pH of
the lysed cell composition was adjusted to 10.5 by adding 6N NaOH.
NaCl in an amount of 2% by weight of the cell broth was added and
heated to 90.degree. C. and held for 22 hours. An oil-containing
emulsion was formed and separated from the lysed cell composition
by heating the oil-containing emulsion and lysed cell composition
to 80.degree. C. and then centrifuging (Alfa Laval Disc Stack
Centrifuge, LAPX 404/Clara 20). The extraction yield was 90.9%. The
oil-containing emulsion contained 1.7% free fatty acids. The
oil-containing emulsion was placed in a 20 L tank with nitrogen
blanketing and was heated to 50-55.degree. C. and 50% citric acid
was added in an amount of 0.3% by weight of the emulsion and held
for 15 minutes. The oil-containing emulsion was further heated to
60-65.degree. C. and NaOH was added in an amount of 12.5% by weight
of the free fatty acid composition and weight of the
oil-containing, and held for 30 minutes to refine the emulsion. The
oil was separated from the emulsion by centrifuging. The refining
yield was 78.2%. The total yield was 78.2%.
Example 10
[0164] An unwashed cell broth (86.3 kg) containing microbial cells
(Schizochytrium sp.) was pasteurized at 60.degree. C. for 1 hour.
The cells were lysed by adding 6N NaOH to pH adjust the broth to
7.5 and Alcalase.RTM. enzyme (available from Novozymes
(Franklinton, N.C.)) was added in an amount of 0.5% based on weight
of the cell broth, agitated at a speed of 185 RPM, heated to
60.degree. C. and held for 2 hours with pH controlled at 7.5 with
6N NaOH. While maintaining the agitation, the pH of the lysed cell
composition was adjusted to 10.5 by adding 6N NaOH. NaCl in an
amount of 2% by weight of the cell broth was added and heated to
90.degree. C. and held for 2 hours. An oil-containing emulsion was
formed and separated from the lysed cell composition by heating the
oil-containing emulsion and lysed cell composition to 80.degree. C.
and then centrifuging (Alfa Laval Disc Stack Centrifuge, LAPX
404/Clara 20). The extraction yield was 96.9%. The oil-containing
emulsion had an AV of 1.5, a PV of <0.1 meg/kg and contained
0.87% free fatty acids. The oil-containing emulsion was placed in a
20 L tank with nitrogen blanketing and was heated to 50-55.degree.
C. and 50% citric acid was added in an amount of 0.3% by weight of
the emulsion and held for 15 minutes. The oil-containing emulsion
was further heated to 60-65.degree. C. and NaOH was added in an
amount of 12.5% by weight of the free fatty acid composition and
weight of the oil-containing emulsion, and held for 30 minutes to
refine the emulsion. The oil was separated from the emulsion by
centrifuging. The total yield was 92.1%. The refined oil had an AV
of 5.2, a PV of 0.52 meg/kg and contained 0.24% free fatty
acids.
TABLE-US-00003 TABLE 3 Comparison of oil-containing emulsion and
refined oil Emulsion Refined oil Moisture 23.8% 0.2% Fat 71.9%
100.4% Free Fatty Acid 0.9% 0.2%
Example 11
[0165] The extraction yields and coalescence times for the examples
provided herein are compared as to a current process (two
examples).
TABLE-US-00004 TABLE 4 Coalescence Times Process Extraction Yield
Time (hr) Example 1 87.2% 20 Example 2 86.3% 22.5 Example 3 94.4%
22 Example 4 99.3% 22 Example 5 93.4% 22 Example 6 93.9% 22 Example
7 91.1% 25 Example 8 82.8% 23 Example 9 90.1% 22.6 Standard #1
91.3% 67 Standard #2 90.2% 43.5
* * * * *