Bacteriophage Production Processes
Bacteriophage Production Processes
Bacteriophage Production Processes
https://doi.org/10.1007/s00253-018-9527-y
MINI-REVIEW
Received: 13 November 2018 / Accepted: 16 November 2018 / Published online: 24 November 2018
# Springer-Verlag GmbH Germany, part of Springer Nature 2018
Abstract
High quantities of bacteriophages are currently used in the food industry and agriculture. However, growing antibiotic resistance
of bacteria has recently awakened the interest to use bacteriophages for the treatment of bacterial infections in humans indicating
that even higher quantities will be required in the future. High demand combined with a wide range of applications requires also
efficient bacteriophage production processes operating at low production costs and with high productivity. To achieve this goal,
different approaches were introduced and extensive studies of various parameters affecting bacteriophage formation were
investigated. In this mini-review, we provide a short overview about different operation modes of bacteriophage production
such as batch, semi-continuous and especially continuous with the pros and cons of each. We present factors affecting bacterial
physiological state, its effect on phage formation and provide a description of methods for determination of bacteriophage growth
parameters, through which bacteriophage formation is obtained. Understanding of described phenomena and inclusion of
potential occurrence of mutations and selection in continuous systems enables evaluation of continuous process productivity
and its optimization.
Keywords Bacteriophage production . Continuous bioprocess . Bacteriophage growth parameters . Bacteria physiological state
Besides the use of phages for the treatment of bacterial Phage cultivation
infections in humans or for the treatment of bacterial infec-
tions in animals (Barrow 2001), phages can be implemented Cultivation of phages is traditionally performed in shaker
also in many other fields. The use of phages has emerged in flasks or in stirred tank bioreactors (Sargeant 1969).
agriculture against plant infections (Balogh et al. 2010), where Especially in a stirred tank bioreactor, phages can be produced
a product like AgriPhage™ is implemented (Monk et al. in different operation modes: batch, semi-continuous, and
2010). Phages have an important role in the food industry in continuous. A description of phage production using different
increasing safety and preventing contamination of food. For modes of operation and their advantages and disadvantages
example, phage products like LISTEX™ P100 (Chibeu et al. were recently presented by Agboluaje and Sauvageau (2018).
2013) and ListShield™ (Monk et al. 2010) are used to prevent In batch mode, high phage concentrations can be achieved,
the growth of Listeria monocytogenes while product but changes in the conditions during the process and especial-
EcoShield™ is used to prevent contamination with ly long preparation time, including cleaning, decrease its over-
Escherichia coli O157:H7 (Monk et al. 2010). Besides treat- all productivity (Agboluaje and Sauvageau 2018). This can be
ment of food products, phages are also used for control and overcome by the implementation of continuous production.
detection of different bacterial strains such as Campylobacter However, the process of switching to continuous biotechno-
jejuni (Hagens and Loessner 2007) and Salmonella through logical processes, especially in biopharmaceuticals produc-
products like SALMONELEX™ and BacWash™ (Ly- tion, is demanding due to an increased complexity
Chatain 2014). A similar application is extended also in clin- (Jungbauer 2013; Rathore 2015). But once implemented this
ical diagnostics for detection and typing of bacterial pathogens difficulty is compensated by higher productivity and reduced
(Schofield et al. 2012), where a system like Vidas UP® was costs. In addition, better quality of a product and its consis-
developed (Hagens and Loessner 2014). Phages are also in- tency is obtained, due to easier control (Rathore 2015).
teresting as potential carriers of vaccines (Haq et al. 2012). Following this objective, one of the approaches for obtaining
Detailed description of potential use and different phage ap- high final phage concentrations is a semi-continuous two-
plications is beyond the scope of this review, since extensive stage self-cycling process (Sauvageau and Cooper 2010). In
information can be found in many excellent reviews published this setup, bacteria are grown in the first bioreactor, operating
elsewhere (Marks and Sharp 2000; Matsuzaki et al. 2005; however in a batch mode. Before bacteria reach stationary
Clark and March 2006; Jones et al. 2007; García et al. 2008; phase, half of the bioreactor media containing bacteria is trans-
Letchumanan et al. 2016; Criscuolo et al. 2017). ferred into the second bioreactor. Their infection is initiated
Due to a widespread use of lytic phages and increasing with the portion of phages produced in the second bioreactor
industrial interest in the use of lysogenic phages (Yosef et al. and intentionally left from an earlier production cycle
2014; Harrison and Brockhurst 2017) further optimization of (Sauvageau and Cooper 2010; Agboluaje and Sauvageau
phage production processes is needed to increase productivity 2018). Significant increase in productivity is demonstrated,
and consequently decrease production costs. Significant diver- which could be further improved when bacterial cells are
sity of phage and bacteria systems (Clokie et al. 2011) dictates immobilized in alginate gel due to easier separation from the
a need for a specific in-depth research about production of each phages (Roy et al. 2018). However, the self-cycling system
individual system such as e.g. lytic phage T4 production requires a high level of control and monitoring (Sauvageau
(Smrekar et al. 2008; Sauvageau and Cooper 2010; Nabergoj and Cooper 2010; Agboluaje and Sauvageau 2018).
et al. 2018a), lysogenic phage production, such as lambda Operational complexity is significantly reduced
phage, where stress like the temperature shift, can cause a implementing real continuous phage production process omit-
transition between lysogenic to a lytic cycle (De Czekala ting cycles. The simplest approach consists of a single biore-
et al. 1972; Clark et al. 1986) and M13 filamentous phage, actor, also called chemostat. In such setup, there is a continu-
used in industrial applications due to its long-term viability ous flow of media through the bioreactor. Bacteria are intro-
and importance in phage display (Branston et al. 2011; duced to the system and allowed that steady state is achieved,
Warner et al. 2014). To optimize large-scale phage production, followed by an addition of phages. Ideally, robust steady state
it is important to understand the interactions between bacteria is achieved, continuously producing phages. However, long-
and phage and its reproduction process, which can be lytic, term continuous production of phages in a single-stage biore-
lysogenic, or in some cases non-lytic for filamentous phages. actor proved to be unfeasible, due to the long-term simulta-
In the present review, we try to give an overview about neous presence of phages and bacteria, resulting in spontane-
possible operation modes for phage production with a special ous mutations of both (Novick and Szilard 1950; Chao et al.
emphasis on continuous processes. Taking into account spec- 1977; Varon 1979; Lenski and Levin 1985; Spanakis and
ificity of bacteria–lytic phage interactions and especially the Horne 1987). The resistance of bacteria is caused by the loss
effect of bacteria physiological state on phage formation, the or modification of the specific phage receptors. Phages adapt
productivity of continuous systems is discussed. to bacterial mutations avoiding resistance. This dynamics is
Appl Microbiol Biotechnol (2019) 103:685–694 687
reflected initially in population oscillations that can later result connected bioreactors, again to prolong contact time and in-
in a stable state (Bohannan and Lenski 1997; Mizoguchi et al. crease the degree of infection (Mancuso et al. 2018).
2003). Therefore, chemostat is an effective tool to study co-
evolution of bacteria and phage system or coevolution of mul-
tiple phages and single bacteria. Coevolution, which enables Effect of bacteria growth conditions on phage
increased species diversity, is directly affected by cultivation production
conditions, for example, resource availability, which is in
chemostat controlled by dilution rate (Forde et al. 2008; To obtain optimal continuous production of phages, besides
Koskella and Brockhurst 2014). It was theoretically and ex- operation mode, also operating conditions (such as tempera-
perimentally demonstrated that in the chemostat, even under ture, pH, feed regime, bioreactor size, and configuration) af-
single substrate limiting conditions, multiple quasispecies of fecting bacterial growth environment and by this indirectly
bacteria and phages can coexist (Bohannan and Lenski 2000; phages formation, should be considered. Differences in phage
Weitz et al. 2005). Alternativelly, complex dynamics between concentration found under different growth conditions clearly
bacteria and phages in chemostat can result in bacterial resis- indicate that bacteria physiological state affects phage forma-
tance and extinction of phage as reviewed by Dennehy (2012). tion rate (Hadas et al. 1997). For this reason, the studies under
Since chemostat is a useful system to investigate resistance non-optimal bacterial growth conditions were performed
development in bacteria and phage, it can also serve for eval- (Hadas et al. 1997; You et al. 2002; Golec et al. 2014;
uation of phage therapy efficacy, where the appearance of Nabergoj et al. 2018b). Obtained results are not only impor-
resistant bacteria represents main drawback (Kunisaki and tant for the design of the production process, but also for
Tanji 2010). different phage applications. For example, in the food industry
Clearly, for a long-term robust phage production, mutations where phages are used for suppression of bacteria, changes in
have to be minimized. This was addressed by developing physiological states of bacteria due to environment conditions
multi-stage connected bioreactors, introduced already in (e.g., changes in temperature, substrate limitation) may lead to
1966 (Jacobson and Jacobson 1966). Setup consisted of a a reduced infection efficiency and consequently poor elimina-
bioreactor where bacteria are continuously growing. In the tion of contamination (Fister et al. 2016). Furthermore, it is
second bioreactor, the flow of bacteria from the first bioreactor essential to investigate the effect of media composition since
is mixed with a continuous flow of phages needed for infec- certain components such as salt concentration and type of
tion. The second bioreactor is connected to several consecu- ions, as well as presence of organic cofactors such as amino
tive bioreactors to ensure long enough residence time, what acid L-tryptophan affect phage adsorption (Ellis and Delbrück
allows all bacteria cells to lyse and produce phages, before 1939; Anderson 1949; Adams 1959; Tucker 1961; Storms
they are washed out of the system. Although the possibility et al. 2010; Mojica and Brussaard 2014). Media composition
of continuous phage production was successfully also significantly affects bacteria physiological state, includ-
demonstrated, the occurrence of resistant bacterial mutants ing cellular composition and metabolism and thereby also
was not completely eliminated. Husimi et al. (1982) presented phage formation (Adams 1959; Kutter et al. 1994; You et al.
a similar configuration with some important modifications 2002; Guttman et al. 2005; Choi et al. 2010; Taj et al. 2013;
resulting in the elimination of bacterial mutations. They de- Egli 2015). In the case of extreme substrate limitation, phage
signed a continuous system consisting of only two connected formation can be completely stopped, despite infection, as is
bioreactors called cellstat. In the first one, bacteria are contin- the case in hibernation mode (Bryan et al. 2016).
uously growing and pumped into the second bioreactor, where Due to a plethora of factors influencing bacterial physio-
phages are located to interact with them. Their system differs logical state in many different ways, making any general con-
from the previous configuration as there is no continuous flow clusion almost impossible, several studies focused on the in-
of phages into a cellstat. More importantly, the occurrence of fluence of bacteria physiological state on phage production,
bacterial mutations is overcome by the use of high dilution keeping all parameters but limiting component constant
rates in the second bioreactor, being above the maximal (Gáspár et al. 1981; Hadas et al. 1997; You et al. 2002;
growth rate of bacteria cultivated in the first bioreactor. This Nabergoj et al. 2018b). Gáspár et al. (1981) studied its influ-
can be achieved with lower volume in the second bioreactor in ence by determining the number of formed phages from bac-
comparison to the volume of the first bioreactor. In this way, terial cells withdrawn at different stages of the batch process,
bacteria that are generated in the second bioreactor and could especially during exponential and limitation phase of bacteria
mutate due to a phage presence, are washed out of the system growth. After withdrawal, bacterial samples were immediate-
and can not therefore accumulate. The phages achieve a ly infected with phages and the number of newly formed
steady-state, as they can compensate their outflow by much phages was determined. It was shown that samples withdrawn
faster formation (Wang 2006; Shao and Wang 2008; Lindberg during the exponential growth phase exhibited a similar num-
et al. 2014). The system can be further upgraded into three ber of newly formed phages, while their number was
688 Appl Microbiol Biotechnol (2019) 103:685–694
significantly lower when cells were in limitation growth obtained by fitting experimental data with a mathematical
phase. Furthermore, the study of phage formation with syn- model describing the change of concentration in continuous
chronized bacteria culture in exponential growth phase dem- stirred tank bioreactor after pulse injection (Levenspiel 1999).
onstrated differences even during the cell growth cycle. The Such procedure allows determination of phage growth param-
newly formed cells produced a lower number of phages than eters without affecting bacterial physiological state; therefore,
cells closer to a cell division (Storms et al. 2013). phage growth parameter values accurately reflect the effect of
Despite the fact that chemostat is not suitable for the robust bacteria physiological state and can be used for modeling and
production of phages due to mutations, it represents, besides optimization of continuous phage production.
for coevolutionary studies, also an excellent tool for investi-
gating the effect of physiological state of bacteria on phage
formation, as growth conditions can be precisely regulated
and kept constant over time (Kick et al. 2017). Different but Design of continuous phage production
constant bacterial physiological states in chemostat can be process
achieved by varying a dilution rate (You et al. 2002; Golec
et al. 2014; Nabergoj et al. 2018b), therefore its effect on To design continuous phage production process a mathemat-
phage formation can be studied in details. Formation of lytic ical description is required. The mathematical model enables
phages is most commonly described through three phage prediction of a system dynamics and influence of each specific
growth parameters: latent period, burst size, and adsorption or combination of process parameters. As such, a single model
constant (Adams 1959). Adsorption constant (δ) is a constant can be used for designing the process for different bioreactor
describing rate of adsorption of phages on bacterial cells; burst configurations, scale up and optimization. Accurate process
size (b) represents a number of phages formed from a single description requires a specific description of bacteria–phage
infected bacterial cell, while latent period (L) represents the dynamics. Because lytic phages are the most promising can-
time between infection and cell lysis. Their values are deter- didates for phage therapy (Abedon et al. 2011), many re-
mined through measurement of phage concentration as report- searchers have focused on mathematical modeling of their
ed elsewhere (Hyman and Abedon 2009). Briefly, the bacte- dynamics (Campbell 1961; Grossi et al. 1977; Lenski 1988;
rial sample is taken from a bioreactor and transferred into an Abedon et al. 2001; Santos et al. 2014; Storms and Sauvageau
Eppendorf tube, where cells are infected with phages. 2015; Krysiak-Baltyn et al. 2016) that includes adsorption of
Determination of adsorption constant is carried out by taking phages onto bacteria, followed by the injection of phage ge-
small samples from the Eppendorf tube in short time intervals. nome into bacteria cell. Phage genome begins to control bac-
The bacterial cells are removed and free phage concentration teria metabolism that leads to a synthesis of progeny phages.
is determined via plaque assay to determine its decrease over The final stage of infection is bacteria cells lysis, when new
time (Kropinski et al. 2009). For determination of latent period phages are released (Adams 1959). Commonly, mathematical
and burst size, so-called one-step growth experiment is per- models about predators and prey (Lotka 1925; Volterra 1926)
formed (Hyman and Abedon 2009). After infection, bacterial serve as a basis of such description. Campbell (1961) and
cells and phages are left mixed for a few minutes until adsorp- Levin et al. (1977) extended that model by inclusion of latent
tion is mostly completed. Free phages are removed from in- period and variations in bacteria concentration due to a limi-
fected bacterial cells by centrifugation, while infected cells are tation of resources. The mass balance equation of lytic phage
resuspended in fresh medium. Concentration of newly formed growth based on phage growth parameters, proposed original-
phages over time is determined, again via plaque assay. In ly for the continuous system by Levin et al. (1977), was mod-
chemostat experiments, infected cells are returned into a bio- ified by Bull (2006) to describe the change in phage concen-
reactor, after phage removal, in order to minimize the effect of tration (P) over time:
sampling on bacterial cells (Golec et al. 2014). Nevertheless, dP
since the determination of phage growth parameters requires ¼ −Pðm þ δX Þ þ bδX ∙PL e−dL ð1Þ
dt
the withdrawal of bacteria from the bioreactor, their physio-
logical state can be affected, and consequently, phage growth Equation 1 requires values of three phage growth parame-
parameter values might not reflect the real influence of bacte- ters (adsorption constant δ, burst size b and latent period L),
ria physiological state. An alternative experimental approach the intrinsic death rate of cells (d), the death rate of free phages
for determination of those parameters in a continuous process (m) and bacteria concentration (X). The first term of Eq. 1
was introduced by Gáspár et al. (1979). Once steady-state of B−P(m + δX)^ represents a disappearance of phages due to
bacteria is achieved, an injection of phages directly into the adsorption and cell death rate, while the second term BbδX ·
bioreactor is performed. Sampling from the bioreactor is car- PLe−dL^ represents the formation of new phages through cell
ried out at a certain time interval and free phage concentration lysis diminished for a portion of cells, which die during t-L
is determined. Values of phage growth parameters are time interval without phage release. Although phage
Appl Microbiol Biotechnol (2019) 103:685–694 689
formation is a discrete process, it can be approximated accu- introducing free phage concentration in terms of phage growth
rately over longer period of time by an exponential increase parameters (Bull et al. 2006):
that can be expressed according to Eq. 2 (Bull 2006):
DP
P ¼ P0 ∙e λt
ð2Þ X∙ðbe−LDP −1Þ−
D2 δ
Pr ¼ P ∙ ð6Þ
δ D P
Equation 2 assumes constant concentration of bacteria, X∙ð1−e−LDP Þ þ
thus only the effect of phage multiplication without cell δ
growth is considered. Although phages have no metabolism,
where Dp is dilution rate in the second bioreactor of the
they are able to catalyze their own formation through the
cellstat. Dilution rate, which represents the bacterial physio-
growing bacteria, therefore their increase can be considered
logical state, affects phage growth parameters and conse-
as an autocatalytic reaction (Northrop 1938). According to
quently also cellstat productivity. The effect of dilution rate
this conclusion Eq. 2 represents an analogy to the growth of
in either first or second bioreactor was shown for the minia-
microorganisms, being a real autocatalytic process that can be
turized system (Nabergoj et al. 2018a) and for a system of
written as a reaction of a first-order kinetics (Eq. 3):
larger scale (Mancuso et al. 2018). Nabergoj et al. (2018a)
dX conducted experiments for two configurations of cellstat. In
¼ X ∙μ or X ¼ X 0 ∙eμt ð3Þ the first configuration, both bioreactor volumes were kept
dt
constant and dilution rate was changed by changing the flow
where μ [h−1] is a specific growth rate of microorganisms. rate through both bioreactors among experiments, therefore
Phage population growth rate λ therefore represents an analog the physiological state of bacteria in the first bioreactor was
to bacteria specific growth rate (Eq. 3). variable between experiments (Nabergoj et al. 2018a). In the
Combining Eqs. 1 and 2, one can correlate phage popula- second configuration, the flow rate through the system was
tion growth rate λ with phage growth parameters to obtain Eq. constant, while the volume of the second bioreactor was
4 (Bull 2006): changed between experiments, affecting only dilution rate in
the second bioreactor, therefore having constant physiological
λ ¼ −m þ δX be−LðλþdÞ −1 ð4Þ state of bacteria in the first bioreactor (Nabergoj et al. 2018a).
Results showed that for each type of experiments an optimal
According to Eq. 4 phage population growth rate λ is dilution rate to obtain the highest productivity exists and that
completely determined by cell concentration, cell death rate, in configuration with constant bacteria physiological state
and four phage growth parameters (latent period, burst size, higher productivity is achieved (Fig. 1). Furthermore,
adsorption constant, and phage death rate). Assuming that in a Mancuso et al. (2018) investigated the effect of dilution rate
chemostat (especially at high dilution rates) intrinsic death rate in the first bioreactor, therefore changing physiological state
of free phages (m) and intrinsic death rate of bacterial cells (d) of bacteria, wherein the dilution rate in the second reactor was
are negligible, the Eq. 4 can be further simplified by setting kept constant. Similar trend of productivity and phage concen-
(m) and (d) to 0 (Podgornik et al. 2014). By developing cor- tration in dependence of dilution rate was demonstrated for
relations between phage growth parameters and dilution rate both miniaturized and larger system (Nabergoj et al. 2018a;
(D) in a chemostat (Nabergoj et al. 2018b), phage growth Mancuso et al. 2018). Configuration developed by Mancuso
parameters in Eq. 4 can be expressed in terms of dilution rate. and colleagues contained also the third bioreactor connected
Due to a rather complex structure of derived equation, original to the second one, what resulted in the higher phage concen-
expression was simplified by Eq. 5, to explicitly express the trations (Mancuso et al. 2018).
effect of dilution rate (therefore of bacteria physiological state) Although operation under optimal dilution rate would pro-
on phage population growth rate λ (Nabergoj et al. 2018b). vide maximal phage production, used mathematical models
λ ¼ λmax ∙D=ðK λ þ DÞ ð5Þ provide no information about the phage consistency since they
did not take into account potential occurrence of mutations.
Similarly, correlations connecting phage growth parame- While bacteria mutations can not accumulate in a cellstat as
ters and normalized bacteria specific growth rate (μ/μmax), dilution rate in the second bioreactor exceeds maximal specif-
were recently derived for a batch process (Krysiak-Baltyn ic bacteria growth rate (Husimi et al. 1982; Schwienhorst et al.
et al. 2018). 1996; Lindemann et al. 2002), this is not the case for phages.
Derived correlations can be used for determination of the Due to spontaneous mutations, certain heterogeneity might
system productivity. Productivity Pr of a continuous system is already be present in the initial phage population (Labedan
generally defined as a product of free phage concentration and and Legault-Demare 1974; Domingo et al. 1978; Storms and
dilution rate (Dunn et al. 1992). The productivity of cellstat Sauvageau 2014). Such subpopulations can differ in their af-
can be calculated from Eq. 6 (Podgornik et al. 2014), when finity toward bacterial host cells that can in extreme case even
690 Appl Microbiol Biotechnol (2019) 103:685–694
Fig. 2 Phase diagram of the steady-state phage population consisting of boundaries of the steady-state population to washout state in
two phage strains (P1 and P2) in cellstat. Abscissa: time of temperature dependence of the volume (Vc): (a) Vc = 20 ml and (b) Vc = 6 × 1018 ml.
oscillation τ and ordinate: dilution rate Dc. Boundaries between phases of Reprinted from [Journal of Theoretical Biology 168, Aita T, Husimi Y,
pure single phage population are divided with solid lines. Dashed-dotted Period dependent selection in continuous culture of viruses in a periodic
line presents the coexistence phase. Dashed lines (a) and (b) show environment, 281–289, Copyright (1994) with permission from Elsevier
Appl Microbiol Biotechnol (2019) 103:685–694 691
Besides temperature, other limiting resources can also quantities, as well as to drive phage mutations to evolve
serve to induce selective pressure. Effect of cultivating condi- phages being able to kill specific bacterial strain.
tions on the selection process between two lytic phages was
investigated by Bull et al. (2006). In cellstat, the change in the Funding The study was funded by the European Regional Development
Fund and Slovenian Ministry of Education, Science and Sport (project
dilution rate results in different phage concentrations and con-
BioPharm.Si).
sequently, the different ratio between bacteria and phages (dif-
ferent multiplicity of infection—MOI). At high phage concen-
Compliance with ethical standardsThis article does not con-
tration, bacteria become a limiting factor, which results in a tain any studies with human participants or animals performed by any of
competitive advantage of faster adsorbing phage, even in the the authors.
case of superinfection. As a selection criterion, a product of
free phage concentration and adsorption constant, which rep- Conflict of interest The authors declare that they have no conflict of
resents the rate of infection (ROI) of bacteria with bacterio- interest.
phage, was used. Because free phage concentration depends
on phage growth parameters, changing these parameters af-
fects ROI and thus also selection process. Simulations dem- References
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