Intensification and technoeconomic assessment of prodigiosin extractive fermentation using multistage continuous fermentation

Abstract

The demand for natural and safe products has fueled interest in molecules with bioactive properties and low toxicity. Prodigiosin, a red alkaloid produced by various bacterial strains, has gained attention for its antimicrobial and antitumor properties. Traditional production methods often face challenges such as inhibition by the product and high costs. This study explores multistage continuous reactors (MSCR) for competitive prodigiosin production via extractive fermentation. A factorial design was conducted to evaluate dilution rates (0.042 – 0.050 h⁻¹) and mixed reactor volume configurations (1 L – 0.5 L). The optimal system was modeled using kinetic equations, and its economic viability was assessed at different dilution rates. Results demonstrate that the separation of growth and production/extraction stages improved productivity by 30 % and reduced costs by 20 % compared to a single continuous system. These findings suggest that MSCR, particularly in extractive fermentations, holds promise for intensifying prodigiosin production, leading to more economically competitive bioprocesses.