Animal feed comprising biomass produced by aerobic fermentation of microalgae of the class dinophyceae

There also are problems associated with the recovery of fish oils containing DHA for food uses.

Such oils often have a fishy odor and unpleasant tastes associated with the oxidation products of the fatty acids . These tastes and toxicities of peroxides render the oils unsatisfactory for use in edible compositions such as baby food and infant formulas.

Marine microorganisms also are known to contain DHA. In particular, various species of dinoflagellates are known to contain DHA. Harrington et al., "The Polyunsaturated Fatty Acids of Marine Dinoflagellates" J. Protozoal, 17:213-219 (1970), characterize the fatty acid content of eight photosynthetic and one heterotrophic marine dinoflagellates, and-conclude that the dinoflagellates are a primary producer group of docosahexaenoic acid and contribute substantial amounts of that compound to the marine food chain.

Aaronson, et al. , in Algae Biomass (1980), discusses possible use of microalgae as food on pages 581-3, but on p.582, Aaronson, et al., states that microalgal biomass is toxic! Furthermore, growth of microalgal biomass is described by Aaronson, et al., in Figures 1 and 2 on page 594, as producing oxygen rather than taking up oxygen (i.e., the growth is photosynthetic, not "aerobic"). Therefore, Aaronson, et al., does not encourage the production of microalgal biomass by heterotrophic fermentation for use as animal feed. 2a

<img img-format="tif" img-content="drawing" file="IL111174AD00021.tif" id="idf0001" />

Successful cultivation of dinoflagellates to produce an edible oil containing DHA has not been achieved. Dinoflagellates in general are very slow growing and are shear sensitive feuillard et al.,

Dinoflagellates, (1984) Academic Press). The prior art discloses that even a small amount of agitation in the culturing vessel reduces growth of the cultures. However, such agitation would be necessary to achieve adequate oxygenation in order to maximize growth for commercial production. DHA is thought to be essential for the proper brain and vision'development of infants because, as noted above, it is the most abundant long .chain PUFA in the brain and retina. Although a metabolic pathway exists in mammals for the biosynthesis of DHA from dietary linolenic acid, this pathway is bioenergetically unfavorable [Crawford, P. AOCS. Short 3

Course in Polyunsaturated Fatty Acids and Eicosanoids, pp. 270-295 (1987)] and mammals, like fish, are thought to obtain most of their DHA from dietary sources. In the case of infants, the most likely source would be human milk. Indeed, DHA is the most abundant C20 omega-3 PUFA in human milk. Generally, however, DHA is absent from infant formulas. U.S. Patent No. 4,670,285 does disclose an infant formula containing omega fatty acids. However, the acids utilized therein are obtained from egg or fish (Talapia) oil and have associated therewith the unpleasant characteristics previously described. Furthermore, fish oils generally contain another omega fatty acid, eicosapentaenoic acid (EPA), an undesirable component in infant formulas because of its prolonged anticoagulant effects and its depression of arachidonic levels in infants. This has been correlated with reduced rates of infant weight gain (Carleson et al. INFORM 1:306.) Indeed, EPA levels are very low in human milk (less than one-forth that of DHA).

Accordingly, it is an object of the present invention to provide a single-cell edible oil containing DHA. Preferably this oil will have no significant quantities of other polyunsaturated fatty acids (PUFA's), i.e. greater than about 2% of the total fatty acid content. In general, it is an object of the present invention to produce single-cell oil in commercially viable yields. The oil, characterized herein as a "designer" oil, after extraction can be used in infant formulas, baby foods, dietary supplements and pharmaceuticals.

In addition, it would be desirable to acquire further knowledge of the metabolic pathway of omega fatty acids. Isotopically labeled DHA would be of 4 great utility in this regard. However, to date, no method has been known to produce aoundant quantities or isotooica-liy labeled DHA. Thus, rt. also.rs an object of the present .invention to provide r so top really labeled DHA in sufficient quantities ro uncerrake such research.

Summary of the Invention

The present invention relates to an animal feed comprising biomass produced by aerobic fermentation of microalgae of the class Dinophyceae.

The present invention further concerns a method of producing single cell biomass for use in animal feed, said biomass comprising edible oil containing at least about 70% triglycerides wherein at least about 20% of the fatty acid residues are DHA, comprising: cultivating microalgae of the class Dinophyceae capable of producing said edible oil in an aerated fermentor to achieve a cell density of at least about 10 grams biomass per liter of nutrient solution, said fermentor preferably containing a nutrient solution having a limiting nitrogen source and an oxygen level of at least about 10% of air saturation level, wherein the concentration of the nitrogen source in the nutrient solution is limited sufficiently to induce said microalgae to produce said edible oil at a concentration of at least about 1.5 grams per liter of nutrient solution, and harvesting microalgal biomass from said fermentor.

Passages of the description which are not within the scope of the claims do not constitute a part of the invention. 5

Brief Description of the Drawings Figures 1, 2 and 3 are graphic illustrations of C, cohnii biomass accumulation over time with the addition of various nutrients. 5 Detailed Description of the Best Mode

Of Practicing the Invention

In accordance with the present invention, microorganisms capable of producing a single cell oil containing DHA are cultivated in a fermentor in a 10 nutrient solution capable of supporting the growth of such organisms. Preferably the single cell oil will contain at least about 20% by weight DHA.

Any microorganisms capable of producing a singlecell edible oil containing DHA can be used in the 15 present invention. For example, photosynthetic diatoms can be used. Preferred microorganisms are marine dinoflagellates, including Crypthecodinium sp. Especially preferred is Crypthecodinium cohnii. an obligate heterotroph requiring a reduced carbon source 20 for growth. C. cohnii is preferred because it contains a fatty acid profile in which DHA is the only PUFA present in sufficient quantities (greater than about 1% of the total amount of PUFAs). Samples of this organism, designated MK8840, have been deposited with 25 the American Type Culture Collection at Rockville,

Maryland, and assigned accession number 40750. As used herein, microorganism, or any specific type of microorganism, includes wild strains, mutants or recombinant types. Any microorganism which produces 30 enhanced levels of oil containing DHA is considered to be within the scope of this invention. One of the features of the present invention is its recognition of the edible oil-producing capability of microorganisms 6 such as dinoflagellates and the attendant solution to the problem of maintaining a reliable, economic source of such oils. Accordingly, wild-type and recombinant microorganisms designed to produce single cell oil containing DHA are an aspect of this invention. Such recombinant organisms would include those designed to produce greater quantities of DHA in the single cell oil, greater quantities of total oil, or both, as compared to the quantities produced by the same wild type microorganism, when provided with the same substrates. Also included would be microorganisms designed to efficiently use more cost-effective substrates while producing the same amount of single cell oil containing DHA as the comparable wild-type mi croorgani sm.

In general, those of skill in the art would not consider C. cohnii a suitable organism for cultivation in a fermentor. Previous workers have commented on the extremely complex mixture of nutrients required to successfully cultivate C. cohnii. Gold et al. Protozoal, 13:255-257 (1966); Guillard, et al. in "Dinoflagellates", Academic Press (1984); Henderson, et al., Phytochemistry 27:1679-1683 (1988). In contrast, the present invention achieves the cultivation of DHA-producing microorganisms in a simple medium containing glucose and yeast extract. Use of these components in a solution such as seawater provides economically significant growth rates and cell densities. For example, during the course of a 3-5 day fermentation, C. cohnii cell densities of at least 10 grams of biomass per liter of solution, and typically from 20 to about 40 grams per liter, can be attained. Such densities have not heretofore been attainable. 7

Although cultivation can occur in any suitable fermentor, preferably the organism is grown either in a stirred tank fermentor (STF) or in an air lift fermentor (ALF), both types known to those of skill in the art. When a STF is selected, agitation is provided using either Rushton-type high efficiency turbines or pitched-blade or marine impellers. Agitation and sparging renew the supply of oxygen to the microorganisms. The rate of agitation normally is increased as the biomass increases, due to the increased demand for oxygen. It is desirable to keep the tip speed at not greater than about 500 cm/sec, preferably not greater than about 300 cm/sec.

Selection of strains of microorganisms which are capable of withstanding greater tip speeds without undergoing shear is within the purview of those of skill in the art. The use of such strains is expressly included in this invention.

As noted above, seawater is an acceptable medium for the nutrient solution. The seawater can be either natural, filtered or an artificial mix, each of which can be diluted to reduced salinities, such as 1/2 to 1/4 normal strength, with tap water or concentrated to 2 times normal strength. A preferred example is Instant Ocean® (IO) brand artificial seawater.

Although C. cohnii is a marine microorganism, some growth has been observed in zero salinity. The use of variants which grow well in reduced salinities is specifically encompassed by this invention.

Micronutrients can be added and may be required at low salinities. However, such micronutrients are known to those of skill in the art and generally are present in seawater or tap water. If the organism selected is 8 heterotrophic, such as C. cohnii. then a carbon source is added.

Preferably, after addition of the seawater medium to the fermentor, the fermentor containing the medium is sterilized and cooled prior to adding the nutrients and a seeding population of microorganism. (Although it is acceptable to sterilize the nutrients together with the seawater, sterilization in this manner can result in a loss of available glucose.) The nutrients and microorganism can be added simultaneously or sequentially.

An effective seed concentration can be determined by those of skill in the art. When a STF is used, the addition of a population of from about .05 to 1.0 grams of dry weight equivalent per liter at the beginning of the fermentation is preferred. This is about 106 cells per ml. Thus, for a 30 liter fermentor, 1-3 liters of seeding media, containing viable cells at a density of 20g dry weight per liter would be added.

Oxygen levels preferably are maintained at a D.O. of at least about 10% of air saturation level. Biosynthesis of DHA requires oxygen and, accordingly, higher yields of DHA require D.O. levels at from about a 10% to 50% of air saturation levels. Agitation tip speeds of 150-200 cm/sec in combination with an aeration rate of 1 WM (volume of air/volume of fermentor per minute) provides D.O. levels of from about 20% to about 30% at biomass densities of about 25 g dry weight/liter of culture. Higher cell densities may require higher D.O. levels, which can be attained by increased aeration rates by O2 sparging, or by increasing the air pressure in the fermentor.

Acceptable carbon sources are known to those of skill in the art. For example, carbon can be provided 9 to C. cohnii in the form of glucose. Other heterotrophs can use other reduced carbon sources, a matter easily determined by those of skill in the art, and autotrophs utilize carbon dioxide. C. cohnii will also grow on other reduced, more complex, carbon sources. Typically, a fermentation is initiated with about 10-50 g/liter glucose. More glucose is added during the fermentation as required. Alternatively, from about 50 to 150 g, preferably 50 to lOOg glucose/liter initially can be added, thereby minimizing the frequency of future additions. The amount of carbon source provided to other organisms can readily be determined by those of skill in the art.

In addition to a reduced carbon source, a nitrogen source, such as yeast extract (YE), is provided to the medium. Commercially available yeast extract is acceptable. For example, DIFCO or MARCOR brand yeast extract can be used. The yeast extract is an organic nitrogen source also containing micronutrients. Other organic nitrogen sources easily can be determined by those of skill in the art. However, such compounds are generally more expensive than yeast extract. The use of variants capable of growing on urea or nitrates is within the scope of this invention. Typically, the fermentation is initiated with about 6-12 g YE/liter. More YE can be added as required. A typical fermentation run requires from about 8 to 15 g YE/liter over the course of the run. Accordingly, that amount of YE can be added initially with a reduced need for further additions. The precise amount can be determined by those of skill in the art. Generally, the ratio of glucose to YE is from about 2:1 to about 15:1. 10

The cultivation can be carried out at any life-sustaining temperature. Generally C. cohnii will grow at temperatures ranging from about 15°C to 34°C. Preferably the temperature is maintained at about 20-30°C. Strains which grow at higher temperatures are preferred, because they will have a faster doubling time, thereby reducing the fermentation time.

Appropriate temperature ranges for other microorganisms are readily determined by those of skill in the art.

The cultivation can be carried out over a broad pH range, typically from about pH 5.0 to 9.0. Preferably, a pH range of from about 6.0 to about 7.0 is used for the growth phase. A base, such as KOH or NaOH, is used to adjust the media pH prior to inoculation. During the later stages of the fermentation, the culture medium tends to become alkaline. If desired, inorganic acid pH controls can be used to correct alkalinity during the growth phase.

Production of the single cell oil is induced in the dinoflagellates by the imposition of a stationary phase (i.e., by nitrogen depletion or a pH rise). YE deficiencies are caused by providing YE in a limiting amount such that the medium runs out of YE while available glucose remains. The present invention’ recognizes that it is the carbon source to nitrogen source ratio which promotes the efficient production of the single cell oil. Using glucose and YE as exemplary, a preferred ratio of carbon source to nitrogen source is about 10-15 parts glucose to 1 part YE. Similar ratios for other carbon and nitrogen sources can be calculated by those of skill in the art.

After induction of oil production, the culture is grown for about 24 additional hours. During this period of oleosynthesis, the single cell oil containing 11 DHA is being synthesized and visible oil droplets become apparent. Those of skill in the art can readily calculate the time of fermentation required to achieve the expected amount of cell biomass based upon the added amount of YE. When that time has passed, the culture is grown for an additional 24 hours and harvested. In general, the C. cohnii are cultivated for a time sufficient to produce single cell oil, usually from about 60 to about 90 hours, although this time is subject to variation.

From about 15 to 30% of the resultant biomass, using wild-type C♦ cohnii, comprises extractable oil. Strain selection can increase this percentage and such selection is within the scope of this invention. Preferably, the oil comprises greater than about 70% triglycerides having, in general, the following fatty acid composition. 15-20% myristic acid (C1A,o) 20-25% palmitic acid (C16t0) 10-15% oleic acid (C18»i) 30-40% DHA (C22j6) 0-10% others (Other oil components including polar lipids, such as phosphatidyl choline, also may be enriched in DNA.)

The crude oil is characterized by a yellow-orange color and is liquid at room temperature. Desirably, the oil contains at least about 20% DHA by weight and most preferably at least about 35% DHA by weight.

The organisms are harvested by conventional means, known to those of skill in the art, such as centrifugation, flocculation or filtration, and can be processed immediately or dried for future processing.

In either event, the oil can be extracted readily with an effective amount of solvent. Suitable solvents can 12 be determined by those of skill in the art. However, preferred solvents include pure hexane and supercritical fluids, such as supercritical C02.

Extraction techniques using supercritical fluids are known to those of skill in the art and described in McHugh et al., Supercritical Fluid Extraction. Butterworth, 1986. If the extraction solvent is hexane, a suitable ratio of hexane to dry biomass is about 4 liters of hexane per kilogram of dry biomass. The hexane preferably is mixed with the biomass in a stirred reaction vessel at a temperature of about 20-50°C for about 2 hours. After mixing, the biomass is filtered and separated from the hexane containing the oil. Alternatively, a wet biomass paste (30-35% solids) can be extracted directly with more polar solvents, such as ethanol, isopropanol or hexane/isopropanol mixtures. The residual biomass, i.e. the single cell edible oil extracted biomass of the microorganisms, such as C. cohnii, can be used as an animal feed, containing as it does about 35-40% protein, 8-10% ash and 45-50% carbohydrates. Because of this high protein content and the elevated levels of DHA, the whole biomass paste can be used for aquaculture (e.g., shrimp, oysters, fish) feed.

The solvent then is removed from the oil by distillation techniques known to those of skill in the art. Conventional oilseed processing equipment is suitable to perform the filtering, separation and distillation. Additional processing steps, known to those of skill in the art, can be performed if required or desirable for a particular application. These steps also will be similar to those involved in conventional vegetable oil processing and allow the separation of DHA-enriched polar lipid fractions. 13

Isotopically labeled single cell oils, including labeled DHA, can be easily obtained in sufficient quantities to permit research into the metabolic pathways of DHA by the method of this invention. When 13C-glucose or 14C-glucose is provided as the reduced carbon substrate, labeled DHA results.

The present invention also includes food products, such as infant formulas and baby foods, as well as dietary supplements, which contain the single-cell oil containing DHA of the present invention. While those of skill in the art have recognized that infant formulas containing DHA are desirable, the prior art infant formulas contained DHA from fish oil, with its attendant unpleasant tastes and organoleptic characteristics. Furthermore, fish oil supplementation of infant formula includes the addition of eicosapentaenoic acid (EPA), an omega fatty acid known to possess anticoagulant activity and possibly responsible for reduction of arachidonic acid biosynthesis. Such an activity is not desirable in infant formula or baby food and the single cell oil described herein contains no significant quantity of EPA. Food products, such as infant formula, containing the single cell oil of the present invention do not have the unpleasant organoleptic characteristics of fish oil. The food products thus are more readily accepted by infants and adults alike. Preferably the infant formula of the present invention contains about 0.05% by weight of single cell oil containing DHA. The baby food of the present invention> having a more solid constitution, preferably contains about 0.5% by weight of single cell oil containing DHA. In both instances, most preferably, the oil contains at least about 35% DHA. 14

The present invention includes pharmaceutical products including single cell oil containing DHA. Preferably the products contain at least about 35% DHA. Exemplary of such pharmaceutical products is one suitable for use in providing total parenteral nutrition (TPN) to infants or adults. Additionally, dietary supplements containing the single cell oil are encompassed. Preferably, such supplements are in the form of gelatin capsules encapsulating said oil and may be appropriate for pregnant women or breast feeding mothers. This especially may be true for such women who are vegetarians and do not get sufficient amounts of DHA in their diets.

The present invention also includes single cell oil containing DHA. Preferably the single cell oil contains at least about 20% by weight DHA. Most preferably the oil contains at least about 35% by weight DHA.

The present invention having been generally described, reference is had to the following nonlimiting specific examples.

Example 1

Into a 30-liter working volume STF was loaded a medium of one half strength artificial seawater. Six liters of 10 were combined with 18 liters of tap water. The fermentor containing the medium was sterilized and cooled to 28°C. Four hundred ml of concentrated YE (455g/l), 900 ml of glucose syrup (400 g/1) and one liter of inoculum from a seed fermentor containing about 2 x 107 cells/ml or a biomass of 20 g/liter (yielding a final concentration of about 7 x 106 cells/ml or a biomass of about 700 mg/liter), were added to the medium. Agitation was set at 120 cm/sec 15 tip speed and aeration was set at 1 WM (30 liters per minute). Additional glucose syrup (900 ml) was added after 30 hours and another 4.2 liters over the next 42 hours. Thus 6 liters of glucose syrup were added in total. Concentrated YE solution (400 ml) was added at hour 6 and another 1.2 liters were added over the next 48 hours until a total of 2.0 liters had been added.

To maintain the D.O. at greater than 20%, at 24 hours the agitation tip speed was increased to 150 cm/sec and at 48 hours to 160 cm/sec. At 72 hours, the tip speed was increased to 200 cm/sec and the culture was permitted to grow for an additional time sufficient to convert the final charge of glucose into cellular oil. The culturing conditions are depicted graphically in Figure 1. The culture was then harvested by centrifugation with the cell pellet retained. The harvested pellet of cells was frozen and dried (lyophilized) to about a 4% moisture content. Hexane (2.8 liters) was added to the dried biomass and stirred in a glass kettle for 1.5 hours at 50°C. A rotary evaporator was used to remove the hexane, producing about 175 g of crude DHA-containing oil.

Example 2

Into a 350-liter working volume STF was loaded a medium of one half strength artificial seawater made by combining 4.3 kg. of 1.0.® with 230 liters of tap water. The fermenter containing the medium was sterilized and cooled to 28°C. 6.8 liters of concentrated YE (400g/l), 12.5 liters of glucose syrup (400g/l) and 30 liters of C. cohnii inoculum from a seed fermenter (106 cells/ml or a biomass density of about 1.3g/liter) were added to the medium. Agitation was set at 73 cm/sec tip speed and aeration was set at 16 1 WM (280 liters per minute). Additional glucose syrup (12 liters) was added after about 44 hours and another 43 liters over the next 32 hours. Thus, 67.5 liters of glucose syrup were added in total. The glucose additions and the cell growth are depicted graphically in Figure 2.

To maintain the D.O. at greater than 20%, at 44 hours the agitation tip speed was increased to 175 cm/sec and at 55 hours to 225 cm/sec. At 76 hours, the tip speed was decreased to 150 cm/sec and the culture was permitted to grow for an additional time sufficient to convert the final charge of glucose into cellular oil. The culture then was harvested. The harvested cells were dried to about a 4% moisture content.

Hexane was added to the dried biomass and stirred in a glass kettle for 2 hours at 25°C. A rotary evaporator was used to remove the hexane, producing about 700 g of crude DHA-containing oil.

Example 3

Into a 30-liter working volume STF was loaded a medium of full strength artificial seawater made by . 9 combining 565g of 1.0.® with 15 liters of tap water.

The fermenter containing the medium was sterilized and cooled to 28°C. Four hundred ml of concentrated YE (400g/l), 1.9 liters of glucose syrup (400g/l) and 1 liter of C. cohnii inoculum from a seed fermenter (106 cells/ml or a biomass of about 2.0g/liter) were added to the medium. Agitation was set at 80 cm/sec tip speed and aeration was set at 1 WM (20 liters per minute). Additional glucose syrup (1.5 1) was added after 94 hours and another 1.1 liters at 116 hours.

Thus 4.5 liters of glucose syrup were added in total. 17

To maintain the D.O. at greater than 20%, at 52 hours the agitation tip speed was increased to 160 cm/sec.

At 66 hours, stationary phase was induced and in order to accomplish this, the pH was spiked with 4N KOH to 5 7.0 and the agitation tip speed was not further increased for the duration of the run. As shown in Figure 3, the culture was permitted to grow for an additional time sufficient to convert the final charge of glucose into cellular oil. The culture then was 10 harvested. The harvested cells were dried to about a 4% moisture content. Hexane was added to the dried biomass and stirred in a glass kettle for 1.5 hours at 50°C. A rotary evaporator was used to remove the hexane, producing about 65 g of crude DHA-containing 15 oil.