WO2001003647A2 - Microbial process for preparing pravastatin - Google Patents

Abstract

The present invention relates to a new microbial process for the preparation of the compound of formula (I) from a compound of general formula (II) wherein R+ stands for an alkali metal or ammonium ion, by the submerged cultivation of the strain able to 6β-hydroxylate a compound of formula (II) in aerobic fermentation and by the separation and purification of the product of formula (I) formed in the course of the bioconversion, which comprises cultivating a strain of the genera Micromonospora able to 6β-hydroxylate a compound of the general formula (II), wherein R+ is as defined above, on a nutrient medium containing assimilable carbon and nitrogen sources and mineral salts at 25-32 °C, thereafter feeding the substrate to be transformed into the developed culture, then fermenting the substrate until the end of bioconversion, then separating the compound of formula (I) from the culture broth and, if desired, purifying the same.

Description

MICROBIAL PROCESS FOR PREPARING PRAVASTATIN

FIELD OF THE INVENTION

The present invention relates to microbial processes for the preparation of pravastatin.

BACKGROUND OF THE INVENTION

Hypercholoesterolemia has been recognized as a major risk factor for atherosclerotic disease, specifically for coronary heart disease. Biosynthesis of

cholesterol is a major contributing factor to hypercholesterolemia. HMG-CoA reductase

catalyzes the conversion of HMG-CoA to mevalonate in the rate determining step in the

biosynthesis of cholesterol. During the past two decades, 3-hydroxy-3-methylglutaryl-

coenzyme A reductase (HMG-CoA reductase EC. 1.1.1.34) has been extensively studied.

Mevinolin and related compounds biosynthesized by different fungal species have been

found to be competitive inhibitors of this enzyme [Endo, A. et al., J. Antibiotics 29, 1346-

1348 (1976): Endo. A. et al., FEBS Lett. 72, 323-326 (1976): Kuo, CH. et al., J. Org. Chem. 48, 1991-1998 (1983)].

Pravastatin is a member of this family of HMG-CoA reductase inhibitors, along

with compactin, lovastatin, simvastatin, fluvastatin and atorvastatin. Pravastatin was first

isolated as a minor canine metabolite of compactin (Tanaka, M. et al., unpublished) in the

course of metabolic studies of compactin [Aral, M. et al., Sankyo Kenkyusho Nempo, 40, 1-38 (1988)]. Tissue selectivity is a unique characteristic of pravastatin. Pravastatin selectively

inhibits cholesterol synthesis in the liver and small intestine but only weakly inhibits

cholesterol synthesis in other organs. Koga, T. et al. Biochim. Biophys. Acta, 1990, 1045,

115-120. Pravastatin has an advantage of lower toxicity than the other HMG-CoA

reductase inhibitors.

It has been reported that compactin can be converted to pravastatin by microbial

hydroxylation using various genera of fungi as well as bacteria belonging to the genera

Nocardia, of the group Actinomycetes; the genera Actinomudura, of the group

Maduromycetes and the genera Streptomyces roseochromogenes and Streptomyces

carbophilus, among other species of the group Steptomyces (U.S. Patent No. 5, 179,013,

U.S. Patent No. 4, 448,979, U.S. Patent No. 4,346,227, U.S. Patent No. 4,537,859, Japanese Patent No. 58-10572).

A problem is encountered with the use of fungi for the production of pravastatin.

Fungi generally do not tolerate high loads of compactin added in the culture medium,

presumably due to the antifungal activity of compactin [Serizawa, N. et al., J. Antibiotics

36, 887-891 (1983)].

The cytochrome P450 system has been shown to be required for the hydroxylation

of compactin to pravastatin by Streptomyces carbophilus bacteria. [Matsuoka, T. et al,

Eur. J. Biochem. 184, 707-713 (1989)]. A problem with the use of the cytochrome P450

system is that recombinant DNA manipulations of it are difficult because it is a complex of proteins rather than a single protein. There is a need for an improved microbial process for preparing pravastatin that

can tolerate high concentrations of compactin and produce pravastatin in high yield and at

high concentration in the fermentation broth.

SUMMARY OF THE INVENTION

The present invention provides a new microbial process for the preparation of

pravastatin. More particularly, this invention provides a microbial process for the

preparation of pravastatin of formula (I)

(i)

from a compound of the general formula (II)

(II) wherein R⁺ stands for an alkali metal or ammonium ion, with a prokaryote from genus

Micromonospora of the Actinoplanetes group able to hydroxylate a compound of the general formula (II) at the 6β position. DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a new microbial process for the preparation of

pravastatin.

The present invention is the culmination of an investigation undertaken to find a

microorganism that would produce pravastatin at higher concentrations and under more

advantageous conditions than has been possible with known microbial systems. Over

6,000 actinomycete strains were screened. Of these, only ten microorganisms were found

to be capable of hydroxylating the sodium salt of compactin to produce pravastatin. In

particular, the following species had this capacity: Streptomyces violaceus No. 1/43

(Kampfer et al. 1991), Streptomyces rochei No 1/41 (Berger et al. 1989), Streptomyces

resistomycificus No. 1/44 (Lindenbein 1952), Streptomyces lanatus (Frommer 1959),

Streptomyces sp. No. 1/28, Micromonospora sp. No. IDR-P₃, Micromonospora purpurea

No. IDR-P₄ (Luedemann and Brodsky 1964), Micromonospora megalormicea ssp. nigra

No. IDR-P₆ (Weinstein et al 1969), Micromonospora rosaria No. IDR-P₇ (Horan and

Brodsky 1986). Since it was not previously known that species of the Micromonospora

genus were able to convert salts of the acid form of compactin into pravastatin, we

undertook a detailed study the Micromonospora species that screened positive.

Micromonospora is a genus belonging to the actinomycetes taxonomic group of

bacteria. Within the order Actinomycetales and the suprageneric group of Actinoplanetes,

the genus Micromonospora has been shown to be more closely related to sporangia-

forming actinomycetes, such as Actinoplanes and Dactylosporangium, and sharply

distinct from other monosporic genera such as Thermomonospora and Thermoactinomyces, with which it was has been associated. The genera of

Actinoplanetes have similar chemotaxonomic characters and nucleic acid affinities. They

are Gram-positive, non-acid fast organisms growing with nonfragmenting, branched and

septate hyphae of 0.2-1.6 μm in diameter. Aerial mycelium is rarely developed or only

sparse. Genus Micromonospora ørskov. 1923.

Micromonospora chalcea (Foulerton, 1905) form well-developed, branched,

septate mycelium averaging 0.5 μm in diameter. Nonmotile spores are formed singly,

sessile, or on short or long sporophores that often occur in branched clusters. Sporophore

development is monopodial or in some cases sympodial. Aerial mycelium is absent or in

some cultures appears irregularly as a restricted white or grayish bloom. Cell walls

contain meso-diaminopimelic acid and/or its 3-hydroxy derivative and glycine. Xylose

and arabinose are present in cell hydrolysates. Characteristic phospholipids are

phosphatidylethanolamine, phosphatidylinositol and phosphatidylinositol mannosides.

Micromonospora chalcea are aerobic to microaerobic and are chemoorganotrophic. They

are sensitive to pH below 6.0. Growth occurs normally between 20°C and 40°C but not

above about 50°C. ørskov, 1923.

It has been observed that several significantly different species of the genus

Micromonospora are able to hydroxylate compactin at the 6β-position and, thus, it

appears that the ability to hydroxylate compactin at the 6β-position is widely shared by

species of genus Micromonospora. The Micromonospora of the present invention

include wild type and mutant strains that are capable of converting a compactin substrate to pravastatin. Preferred Micromonospora used to further describe certain preferred

embodiments of the invention and to illustrate it with specific examples were selected for their high hydroxylating capacity, which can exceed about 90% at 0.1 g/liter concentration of compactin acid sodium salt. The following strains of Micromonospora

were deposited on April 13, 1999 at the National Collection of Agricultural and Industrial

Microorganisms, Budapest, Hungary under the number NCAIM P (B) 001271 of

Micromonospora purpurea IDR-P₄; NCAIM P (B) 001272, Micromonospora

echinospora ssp. echinospora IDR-P₆; NCAIM P (B) 001273, Micromonospora meg

alomicea ssp. nigra IDR-P₆; and NCAIM P (B) 001274 of Micromonospora rosaria IDR-

p₇-

An isolated Micromonospora species, numbered IDR-P₃, was deposited on

October 13, 1998 at the National Collection of Agricultural and Industrial

Microorganisms, Budapest, Hungary under the number NCAIM P (B) 001268. Strain No.

IDR-P₃ of Micromonospora sp. was isolated from a mud sample of Lake Balaton,

Hungary. In addition to producing pravastatin from compactin sodium salt in high

concentration under conditions suitable to large scale fermentation, this species

biosynthesizes only minor amounts of other structurally related compounds. Thus this species is very well adapted for the industrial production of pravastatin.

The taxonomic features of the cultures of Micromonospora IDR-P₃ are

summarized as follows.

Micromorphological properties: Substrate mycelium is composed of well developed,

more curved than straight, branching filaments. In slide cultures, the monopodial system of branching hyphae (sporophores) may be observed. Spores are single, spherical,

approximately 1.8 μm in diameter and are dispersed evenly on hyphal filaments. Spores

are either sessile or on the end of short sporophores. In broth cultures, spores were not observed on sporulating hyphae, possibly because of the mature spores are released

rapidly into the medium.

Cultural-morphological properties :

Czepak-sucrose agar. Medium growth, the colonies are of reddish color covered

by point-like black sporulating areas.

Glucose-asparagine agar. The growth was recorded as point-like and elevated,

reddish -brown or black colonies. Reddish diffusible pigment.

Nutrient agar. Fair growth, elevated, reddish-brown or black colonies. Reddish-

brown exopigment in the medium.

Yeast extract-malt extract agar (ISP Med. 2): Well developed, elevated and

wrinkled, brown colonies, covered partly with black sporulating areas or with "pseudo-

aerial mycelium" appearing as a restricted whitish or greyish bloom. Brownish or

brownish-red soluble pigment.

Inorganic salts-starch agar (ISP Med. 4): Medium growth of reddish-brown

elevated and wrinkled colonies. Light reddish soluble pigment.

Glycerol-asperagine agar (ISP Med. 5): Growth only in traces, off-white or light

orange colored, flat colonies, light rose soluble pigment.

On some media observing soluble pigment has a particular indicator-character:

being yellow in the acid pH-range and in the basic pH-range slightly turns into dark shade

of reddish color.

Carbon source utilization: Good growth on and positive utilization of L-arabinose, D-

cellobiose, D-fructose, D-glucose, lactose, D-maltose, D-mannitol, D-mannose, α-methyl-

D-glucoside, L-rhamnose, D-ribose, D-sucrose, D-trehalose and D-xylose. Adonitol, dulcitol, myo-inositol, inulin, D-melezitose, D-raffinose are not utilized. Growth with D-

galactose, glycerol, D-melibiose and D-salicin was slightly better than on the negative

control medium.

Nitrogen source utilization: Good growth with yeast extract and NZ-Amine, no

utilization of L-asparagine, L-glutamic acid, NH₄NO₃ and NaNO₃.

Other physiological-biochemical properties: Cellulose and starch are hydrolyzed, milk

is digested strongly. Nitrate reduction test is negative. No growth on potato slices

without calcium carbonate (pH 5.8-6.0).

A preferred form of the invention, base upon our studies of the Micromonospora

strains deposited with the National Collection of Agricultrual and Industrial

Microorganisms, Budapest, Hungary, relates to a new microbial process for the preparation of pravastatin of formula (I)

from a compound of general formula (II),

(H) wherein R⁺ stands for an alkali metal or ammonium ion, by the submerged cultivation of a

strain able to 6β-hydroxylate a compound of formula (II) by aerobic fermentation and by

the separation and purification of the compound of formula (I) formed in the course of the

bioconversion wherein the process comprises the steps of: a) cultivating a microorganism

of the genus Micromonospora able to 6β-hydroxylate a compound of formula (II) -

wherein R⁺ is defined above - in a nutrient medium containing assimilable carbon and

nitrogen sources and mineral salts at 25-32 °C, thereafter b) feeding the substrate until the

end of bioconversion, c) fermenting the substrate until the end of bioconversion, then

d) separating the compound of formula (I) from the culture broth and, if desired,

purifying the same.

According to a yet more preferred embodiment, pravastatin is produced from

either a wild strain or mutant strain of Micromonospora selected from the group

consisting of Micromonospora purpurea IDR-P₄ [NCAIM P (B) 001271],

Micromonospora achinospora ssp. echinospora IDR-P₆ [NCAIM P (B) 001272],

Micromonospora megalomicea ssp. nigra IDR-P₆ [NCAIM P (B) 001273] and

Micromonospora rosaria IDR-P₇ [ NCAIM P (B) 001274]. According to the most

preferred embodiment of the invention, pravastatin is produced with Micromonospora sp. IDR-P₃ [NCAIM P (B) 001268]. The present invention can be carried out by in situ fermentation, that is, by

hydroxylation conducted in the presence of actively growing microorganisms using batch

culture or fed-batch culture techniques.

The hydroxylation may be conducted by employing agitation, such as in shake-

flask culture, or aeration and agitation in fermentors, when the compound of the formula

(II) is added to the growing cultures. In such cases an anti-foaming agent may be

employed.

The microorganisms may be cultivated and maintained using an appropriate

nutrient medium containing carbon and nitrogen sources and inorganic salts and trace

elements. Exemplary assimilable carbon sources include glucose, glycerol, dextrin,

starch, ramnose, xylose, sucrose, soluble starch, etc. Exemplary assimilable nitrogen

sources include soybean meal, corn steep liquor, pepton, yeast extract, meat extract,

ammonium citrate, ammonium sulfate, etc. Inorganic salts such as calcium carbonate,

sodium phosphates, potassium phosphates etc., may also be added to the culture medium.

Preferred media for the growth of microorganisms are described in the examples.

Preferably the culture is an agitated liquid medium. The preferred temperature

range for conducting the hydroxylation is from about 25 °C to 37°C, most preferably

about 25 °C to 32 °C. The preferred pH is from about 6.0 to 9.0, most preferably between

about 7.0 to 8.5. The preferred shaking condition is about 200 rpm to 400 rpm, most

preferably about 250 rpm.

Any compactin concentration can be used that will result in production of

pravastatin. A compactin concentration of between about 0.1 and 10 g/liter, more

preferably between about 0.3 and 3.0 g/liter, is well suited for in situ hydroxylation. The percentage of conversion of compactin to pravastatin is not a critical feature of the

inventive process. However, conversion preferably occurs to the extent of about 30% or

more, preferably about 60% or more and yet more preferably about 90% or more.

The composition of the fermentation broth may be monitored by high performance

liquid chromatographic method (HPLC) using conditions described in the Examples.

Pravastatin can be isolated from the fermentation broth by any method, e.g.,

extraction-reextraction, anion exchange chromatography or precipitation. The following

isolation processes are well suited to isolating pravastin as a biosynthetic product of

Micromonospora. However, these processes are provided for the sole purpose of

completely disclosing the favored modes of obtaining pravastatin starting from compactin

and a strain of the genus Micromonospora and are not intended to limit the invention in

any way.

After finishing the bioconversion, pravastatin can be extracted either from the fermentation broth or from the filtrate obtained after the separation of the bacterium cells.

Bacterium cells can be removed either by filtration or centrifugation. However, it is

advantageous, especially in an industrial scale, to perform a whole broth extraction.

Extraction solvents are any solvent that is not wholly miscible with water. Preferred

extraction solvents have low solubility in water. Especially preferred solvents include

acetic acid esters having a 2-4 carbon atom containing aliphatic alkoxyl moiety, such as

ethyl acetate and isobutyl acetate.

In the course of our experiments it was recognized that pravastatin can be precipitated from an organic extract of the broth as a crystalline salt with secondary

amines. Further, it was found that several secondary amines containing alkyl-, cycloalkyl- , aralkyl- or aryl-substituents are especially well-suited for the salt formation. Among

these, the following secondary amines are the most preferred, in part because of their low

toxicity: dioctylamine, dicyclohexylamine and dibenzylamine.

The method of isolating the organic secondary amine salt of pravastin is

illustrated with dibenzyl amine. Isolation of the dibenzylamine salt is carried out by

adding dibenzylamine in 1.5 equivalent quantity related to the pravastatin content of the

extract, then the extract is concentrated by vacuum distillation to 5% of its original

volume, then another quantity of dibenzylamine is added into the concentrate in 0.2

equivalent ratio. The crystalline dibenzylamine salt is precipitated from the concentrate.

The crystalline crude product is filtered and dried under vacuum, and is clarified with

charcoal in methanol or acetone solution. Pravastatin dibenzylamine salt can be further

purified by recrystallization from acetone.

Pravastatin organic secondary amine salts can be transformed to pravastatin with

sodium hydroxide or sodium alkoxide. A preferred sodium alkoxide is sodium ethoxide.

The isolation of pravastatin via a secondary amine salt intermediate is a simpler

procedure than any of the previously known isolation procedures. During the procedure,

artifacts are not formed. Separation of pravastatin from by-products of the bioconversion

and from the various metabolic products biosynthesized by the hydroxylating

microorganism can be advantageously solved.

Another process for isolating pravastatin from the fermentation broth takes

advantage of the fact that the bioconversion produces pravastatin in its acidic form.

Thus, pravastatin can be isolated from the broth by adsorption on an anion exchange resin

column, preferably from a filtrate of the broth. Strongly basic anion exchange resins like a polystyrene-divinylbenzene polymer carrying quaternary ammonium active groups such

as Dowex^® Al 400 (OH^" form), Dowex^® 1x2 (OH^" form), Dowex^® 2x4 (OH^" form),

Amberlite^® IRA 900 (OH^" form) resins are well suited for absorbing pravastatin free acid

from the broth. The material that absorbs on the ion exchange resin can be eluted from

the column by aqueous acetic acid or a mixture of acetone and water containing sodium

chloride. A 1% solution of sodium chloride in a (1: 1) acetone: water mixture is a

particularly preferred eluent. Pravastatin-containing fractions are combined and the

acetone is distilled off under vacuum. The pH of the concentrate is adjusted with 15%

sulphuric acid to a range of 3.5-4.0 and the acidified aqueous solution is extracted with

ethyl acetate. Pravastatin can be re-extracted from the ethyl acetate extract using a 1/10 to

1/20 volume ratio of 5% sodium hydrogen carbonate or other mildly alkaline basic

solution (pH 7.5-8.0).

Pravastatin can be recovered from the alkaline aqueous extract in a pure form by

column chromatography on a non-ionic adsorption resin. In one method, any residual

ethyl acetate that dissolved in the alkaline aqueous phase during extraction should be

removed by vacuum distillation and then the aqueous extract is loaded on a Dialon HP-20

column. Pravastatin adsorbed on the column is purified by elution with aqueous acetone

in which the acetone content is gradually increased, then the chromatographic fractions

containing pravastatin as a single component are combined and concentrated under

vacuum. The concentrate is clarified with charcoal and lyophilized. The pravastatin is

then crystallized from an ethanol-ethyl acetate mixture, affording pravastatin in a quality acceptable for pharmaceutical application. Another method for isolating pravastatin lactonizes pravastatin to improve

separation from other acidic organic substances in the broth. Before extraction, the pH of

either the fermentation broth or the filtrate of the broth is adjusted to 3.5-3.7 with a

mineral acid, preferably with dilute sulphuric acid. The broth is then extracted with a

water-immiscible organic solvent, preferably an acetic acid ester with a 2-4 carbon atom

containing aliphatic alkoxyl moiety, such as ethyl acetate or isobutyl acetate. The ethyl

acetate extract is washed with water and dried with anhydrous sodium sulphate. Then,

pravastatin is converted to its lactone. The lactone ring closure may be carried out in

dried ethyl acetate solution at room temperature under continuous stirring and using a

catalytic amount of trifluoroacetic acid. Lactone ring closure can be monitored by thin

layer chromatography ("TLC"). After the lactone has formed, the ethyl acetate solution is

washed with 5% aqueous sodium hydrogen carbonate solution and then with water. The

ethyl acetate solution is dried with anhydrous sodium sulphate and ethyl acetate is

evaporated under vacuum. The residue is purified with silica gel column chromatography

eluting with mixtures of ethyl acetate and hexane and gradually increasing the ethyl

acetate content.

The purified pravastatin lactone is converted to pravastatin sodium by hydrolysis

at room temperature in ethanol with an equivalent or more of sodium hydroxide. After

the pravastatin sodium salt has formed, the pravastatin sodium can be precipitated with

acetone. The precipitate is filtered and washed with acetone and w-hexane and dried

under vacuum. The pravastatin sodium can be crystallized from an ethanol-ethyl acetate

mixture to yield pravastatin sodium in a quality acceptable for pharmaceutical application. Another method of isolating pravastatin uses chromatography on Sephadex LH-20

gel. Pravastatin exceeding the purity of 99.5% (measured by HPLC) can be produced by chromatography on Sephadex LH-20 gel.

Having thus described the invention with respect to certain preferred

embodiments, the inventive processes for biosynthesis of pravastatin using

Micromonospora and isolating pravastatin will further be illustrated with the following

examples.

EXAMPLES

High performance liquid chromatography ("HPLC") was performed using

equipment manufactured by Waters^®. HPLC conditions: column packing Waters

Novapack C₁₈ 5μm reverse phase packing; UV detection: λ = 237 nm; injection volume:

10 μl; flow rate: 0.6-0.9 ml/min linear gradient; gradient elution: solvent A = acetonitrile-

0.1M NaH₂PO₄ in water (25:75), solvent B = acetonitrile-water (pH 2 with H₃PO₄)

(70:30). The gradient program is shown in Table 1.

Table 1

Time (min) Flow rate (ml/min.) Eluent A (%) Eluent B (%)

0 0.6 100 0

2 0.7 100 0

20 0.9 0 100

21 0.9 0 100

22 0.9 100 0

27 0.7 100 0 Retention times: pravastatin (Na salt) 10.6 min; compactin (acid form) 19.5 min;

pravastatin (lactone form) 17.3 min; compactin (lactone form) 23.5 min.

Example 1

A soluble starch agar medium ("SM", Table 2) was adjusted to a pH of 7.0 and

then sterilized at 121 °C for 25 minutes.

Table 2

Composition of SM medium

Soluble starch 10.0 g

Yeast extract 5.0 g

Na₂HPO₄ 1.15 g

KH₂PO₄ 0.25 g

KC1 0.2 g

MgSO₄'7H₂O 0.2 g

Agar 15.0 g

Water 1000 ml

The SM medium was then innoculated with Micromonospora sp. IDR-P₃

[NCAIM P (B) 001268]. A spore suspension in distilled water (5 ml) was prepared from

spores obtained from the 7-10 day old, soluble starch agar (SM) slant culture of

Micromonospora sp. IDR-P₃ [NCAIM P (B) 001268].

The suspension was used to inoculate Tl inoculum medium (100 ml, Table 3) in a

500 ml Erlenmeyer flask after adjusting the pH of the Tl medium to 7.0 and sterilization

at 121 °C for 25 minutes. Table 3 Composition of Tl medium

Soluble starch 20.0 g

Yeast extract 10.0 g

CaCO₃ 5.0 g

CoCl₂ ^«6H₂0 2.0 mg

Water 1000 ml

The culture was shaken on a rotary shaker (250 r.p.m.; amplitude: 2.5 cm) for 3

days, at 32 ^CC. Then, 5 ml portions of this inoculum culture were used to inoculate ten

500 ml Erlenmeyer flasks each containing TT medium (100 ml, Table 4) that had been

adjusted to pH 7.0 and sterilized at 121 °C for 25 minutes.

Table 4

Composition of TT medium

Potato starch 30.0 g

Soybean meal 30.0 g

CaCO₃ 5.0 g

CoCl₂*6H₂0 2.0 mg

Palm oil 2.0 g

Water 1000 ml

The bacteria were incubated at 32 °C for 72 hours. The sodium salt of compactin

(50 mg) was then added to each flask in distilled water, the bioconversion was continued

at 32°C for a further 96 hours. The conversion of compactin sodium salt to pravastitin

measured 82% by HPLC. After finishing the fermentation, the cultures were combined. Pravastatin formed

in an average concentration of 410 μg/ml. Pravastatin was isolated as follows. The

fermentation broth was centrifuged at 2500 r.p.m. for 20 min. The supernatant of the

broth and the cells of bacterium were separated. Water (250 ml) was added to the cells of

bacterium and the suspension was stirred for one hour and filtered. The supernatant and

filtrate were combined. The pH was adjusted to 4.0 with 15% sulphuric acid. The acidic

filtrate/supernatant mixture was extracted with ethyl acetate (3x300 ml). The combined

ethyl acetate extracts were washed with water (300 ml), dried with anhydrous sodium

sulphate and concentrated under vacuum to 100 ml volume.

Pravastatin lactone was prepared from pravastatin by adding trifluoro acetic acid

in catalytical amount at room temperature with continuous stirring. Formation of

pravastitin lactone was monitored by TLC: adsorbent: Kieselgel (silica gel) 60 F₂₅₄ DC

(Merck) on aluminum foil backing; developing solvent: acetone:benzene:acetic acid

(50:50:1.5) mixture; detection: phosphomolybdic acid reagent; R_f (pravastatin lactone) =

0.7. After lactonization was complete, the ethyl acetate was washed with 5% aqueous

sodium hydrogen carbonate (2x20 ml), then water (20 ml), and dried with anhydrous

sodium sulphate. Ethyl acetate was evaporated under vacuum. The residue (0.5 g) was

separated by gradient column chromatography on 10 g of Kieselgel 60 adsorbent (column

diameter: 1.2 cm) eluting with ethyl acetate-H-hexane mixtures of increasing polarity.

Pravastatin lactone was eluted from the column with a mixture of 60% ethyl acetate/w-

hexane. The fractions containing pravastatin lactone were combined and evaporated

under vacuum. The residue (230 mg) was dissolved in ethanol (5 ml) and then 110 mole % of sodium hydroxide was added as a 1M ethanolic solution with stirring. Stirring was continued for half an hour at room temperature. The solution was then concentrated to 2

ml volume. Acetone (4 ml) was added to the concentrate. The mixture was kept at +5 °C

overnight. The precipitate was filtered, washed with acetone (2 ml) and then «-hexane (2

ml) and dried under vacuum at room temperature. The resulting crude pravastatin was

dissolved in ethanol. The solution was clarified with charcoal and then pravastatin (170

mg) was crystallized from ethanol-ethyl acetate mixture.

Characterization:

Melting point: 170-173 °C (decomp.)

[α]_D ²⁰ = + 156° (c=0,5, in water).

Ultraviolet absorption spectrum (20 μg/ml, in methanol): λ_max = 231, 237, 245 nm

(log ε = 4.263; 4.311; 4.136).

Infrared absorption spectrum (KBr): v OH 3415, v CH 2965, v C-0 1730, v COO^'

1575 cm^"1.

'H-NMR spectrum (D₂O, δ, ppm): 0.86, d, 3H (2-CH₃); 5.92, dd, J = 10.0 and 5.4 Hz, IH (3-H); 5.99, d, J = 10.0 Hz, IH (4-H); 5.52, br, IH (5-H); 4.24, m, IH (6-H); 5.34,

br, IH (8-H); 4.06, m, IH (β-H), 3.65, m, IH (δ-H); 1.05, d, 3H (2'-CH₃); 0.82, t, 3H (4'-

H₃).

¹³C-NMR spectrum (D₂O, δ, ppm): 15.3, q (2-CH₃); 139.5, d (C-3); 129.5, d (C- 4); 138.1, s (C-4a); 127.7, d (C-5); 66.6, d (C-6); 70.1, d (C-8); 182.6, s (COO^"); 72.6, d

(C-β); 73.0, d (C-δ); 182.0, s (C-F); 18.8, q (2'-CH₃); 13.7, q (C-4').

Positive FAB mass spectrum (characteristic ions): 469 [M+Na]⁺ ; 447 [M+H]⁺.

Negative FAB mass spectrum (characteristic ions): 445 [M-H]^"; 423 [M-Na]^";, mlz 101 [2-methyl-butyric acid-J]. Example 2

Bioconversion medium MT (Table 5) was adjusted to pH 7.0 and sterilized at

121 °C for 25 minutes.

Table 5

Composition of MT Bioconversion Medium

Potato starch 10.0 g

Dextrose 20.0 g

Soybean meal 10.0 g

Yeast extract 10.0 g CaCO₃ 5.0 g

CoCl₂-6H₂0 2.0 mg

Sunflower oil 2.0 g

Water 1000 ml

Ten 500 ml Erlenmeyer flasks each containing MT bioconversion medium (100

ml) were inoculated with the inoculum culture prepared in Example 1 and incubated at

28 °C for 96 hours. The sodium salt of compactin (50 mg) was dissolved in a minimum of

distilled water and added to each flask. Fermentation was continued for 72 hours. Then

another 50 mg of compactin sodium salt in distilled water was added to each of the

cultures and the fermentation was continued for another 72 hours.

The cultures were combined and pravastatin was isolated from the broth by the

following procedure. The combined cultures, containing 750 mg of pravastatin according

to the HPLC assay, were centrifuged at 2500 r.p.m. for 20 min. The separated cells of bacterium were stirred with water (250 ml) for an hour, then filtered. The supernatant and

filtrate were combined and the pH of the resulting solution was adjusted to 3.5-4.0 with 15% sulphuric acid. The solution was extracted with ethyl acetate (3x300 ml). Then

150 mole% of dibenzylamine— calculated for the pravastatin content— was added to the

ethyl acetate extract. The ethyl acetate extract was evaporated to about 30 ml volume and

the suspension was kept overnight at 0-5 °C. Precipitated pravastatin dibenzylammonium

salt was filtered and washed on the filter with cold ethyl acetate and «-hexane and dried

under vacuum. The crude pravastatin dibenzylammonium salt (1.1 g) was dissolved in

acetone (33 ml) at 62-66°C. The solution was clarified with charcoal (0.1 g) for half an

hour. The charcoal was removed by filtration from the solution and washed with warmed

acetone (10 ml). Crystals precipitated from the concentrate and were dissolved again at

62-66°C. The solution was kept at +5° C overnight. The precipitate was filtered, washed

with cold acetone and «-hexane and dried under vacuum. The pravastatin

dibenzylammonium salt so obtained (0.7 g) was suspended in ethanol (10 ml), then 110

mole% of sodium hydroxide was added to the solution as a IM aqueous solution. Stirring of the alkaline solution was continued for half an hour at room temperature. Water (30

ml) was added and the pH of the solution was neutralized. The ethanol was distilled off

under vacuum. The resulting aqueous concentrate was separated by gradient column

chromatography on a column filled with 50 ml of Diaion HP 20 resin (column diameter: 1.5 cm). The column was eluted with acetone-deionized water mixtures, increasing the

concentration of the acetone in 5% increments. Pravastatin could be eluted from the

column with a 15% acetone-deionized water mixture. Fractions were analysed by the

TLC method given in the Example 1 : R_f (pravastatin) = 0.5. Fractions containing pravastatin were combined and the acetone was evaporated under vacuum. Lyophilization of the aqueous residue gave chromatographically pure pravastatin (390

mg).

Example 3

TT/2 medium (4.5 L, Table 6) was sterilized at 121 °C for 45 minutes in a

laboratory fermentor and inoculated with the Micromonospora sp. IDR-P₃ inoculum

shake culture in Tl medium (500 ml) prepared as described in Example 1.

Table 6

Composition of TT/2 Bioconversion Medium Glucose 75.0 g

Soluble starch 50.0 g

Soybean meal 50.0 g

Yeast extract 50.0 g soya peptone 5.0 g CoCl₂ ^»H₂O 2.0 mg

CaCO₃ 5.0 g

Water 1000 ml

The medium was then incubated at 28 °C, aerated with 150 L/h of sterile air and

stirred with a flat blade stirrer at 300 r.p.m. The fermentation was continued for 72 hours

and the sodium salt of compactin (2.5 g) was added to the culture. By the 48^th hour of the bioconversion the compactin substrate was consumed from the fermentation broth.

Additional compactin sodium salt (2.5 g) was added to the culture. The second dose of compactin substrate was consumed in 24 hours. The conversion rate of compactin

sodium salt into pravastatin was 90%. Example 4

TT/1 fermentation medium (4.5 L, Table 7) was adjusted to pH 7.0 and sterilized

at 121 °C for 45 minutes in a laboratory fermentor.

Table 7

Composition of TT/1 Bioconversion Medium

Glucose 125.0 g

Potato starch 25.0 g

Soybean meal 50.0 g

Yeast extract (Gistex) 50.0 g soya peptone 50.0 g

CoCl₂-6H₂O 2.0 mg

CaCO₃ 5.0 g

Sunflower oil 2.0 g

Water 1000 ml

The TT/1 medium was inoculated with the Micromonospora sp. IDR-P₃ inoculum

shake culture (500 ml) prepared as described in Example 1. The culture was then

incubated at 28 °C, aerated with 200 L/h of sterile air and stirred with a flat blade stirrer at

400 r.p.m. for 96 hours. The sodium salt of compactin (2.5 g) was added to the culture as

a sterile filtered aqueous solution. The fermentation was conducted at 28° C. By the fifth day of fermentation the compactin was consumed from the fermentation broth.

Additional compactin sodium (7.5 g) was added in 2.5 g portions intermittently over two

days. The additional compactin sodium salt was completely converted to pravastatin within four days of the first addition. At the end of the fermentation, compactin sodium salt (10 g) was converted to pravastatin (9 g, 90%). Pravastatin at a concentration of 1800 μg/ml was isolated from the broth as follows. The culture broth (5 L) was centrifuged at 2500 r.p.m. for 20 min and the

supernatant was separated from the cells of the bacterium. Water (2 L) was added to the

separated cells and the resulting suspension was stirred for one hour and filtered. The

supernatant and filtrate were combined and passed through a column containing Dowex^®

Al 400 (OH^") resin (300 g, column diameter: 4 cm) at a flow rate of 500 ml/hour. The resin bed was washed with deionized water (1 L). The column was then eluted with a 1 : 1

acetone-water mixture (1 L) containing 10 g of sodium chloride, collecting in 50 ml

fractions. The fractions were analyzed by the TLC method given in the Example 1.

Fractions containing the product were combined and the acetone was distilled off under vacuum. The pH of the concentrate was adjusted to 3.5-4.0 value with 15% sulphuric

acid. The concentrate was extracted with ethyl acetate (2x250 ml). Deionized water (40

ml) was added to the combined ethyl acetate extracts. The pH of the aqueous phase was

adjusted to 7.5-8.0 with IM sodium hydroxide. After 15 min stirring, the aqueous and

ethyl acetate phases were separated. The aqueous alkaline extraction was twice repeated.

The combined alkaline aqueous solutions were concentrated to 50 ml volume and the

residue was separated by chromatography over Diaion^® HP20 (Mitsubishi Co. Japan, 600

ml, column diameter 3.8 cm). The column was washed with deionized water (600 ml), then eluted with acetone-deionized water mixtures, increasing the concentration of

acetone in the eluent in 5% increments. The eluent was collected in 50 ml fractions. The

eluent was analysed by the TLC method given in the Example 1. Pravastatin was eluted from the column in the 15% acetone-deionized water mixture. Fractions containing pure

pravastatin as determined by TLC were combined and the solution was concentrated under vacuum to a volume of 150 ml. The concentrated eluent was clarified by stirring over charcoal (0.6 g) at room temperature for 1 hour. The charcoal was filtered off and

the filtrate was lyophilized. The resulting lyophilised pravastatin (6.5 g) was crystallized

twice from a mixture of ethanol and ethyl acetate. The precipitate was filtered and washed with ethyl acetate (20 ml) and w-hexane (20 ml), and dried under vacuum at room

temperature to obtain chromatographically pure pravastatin (4.6 g).

Example 5

The sterile soluble starch medium SM of Example 1 was innoculated with

Micromonospora echinospora ssp. echinospora IDR-P₅ [NCAIM P (B) 001272]

bacterium strain and incubated for ten days. A spore suspension in distilled water (5 ml) was prepared from spores obtained from the ten day old soluble starch medium and the

suspension was used to inoculate 100 ml of the sterile Tl inoculum medium described in

Example 1 in a 500 ml Erlenmeyer flask. The culture was shaken on a rotary shaker (250

r.p.m., 2.5 cm amplitude) for 3 days at 28°C. Then, 5 ml portions of the obtained culture

were transferred to ten 500 ml Erlenmeyer flasks, each containing 100 ml of bioconversion media TT/1 that had been sterilized by heating to 121 °C for 25 min. The

composition of the TT/1 medium is described in Example 3. Flasks were incubated with shaking on a rotary shaker (250 r.p.m., 2.5 cm amplitude) for 3 days at 25 °C. Compactin

sodium salt (10 mg) was added as a sterile filtered aqueous solution to each of the flasks.

Fermentation was continued for 168 hours at 25 °C. At the end of the bioconversion, the pravastatin content of the fermentation broth was 40 μg/ml as determined by HPLC. Example 6 Inoculation, incubation, fermentation and substrate feeding were carried out with

the Micromonospore megalomicea ssp. nigra IDR-P₆ [NCAIM P (B) 001273] bacterium

strain as described in Example 5. The pravastatin content of the fermentation broth after

168 h was determined to be 50 μg/ml by HPLC.

Example 7

An inoculum culture of the Micromonospora purpurea IDR-P₄ [NCAIM P (B)

001271] bacteria strain (5 ml) was prepared according to the method described in

Example 1. The inoculum culture was used to seed TT/14 medium (100 ml, Table 8) in

500 ml Erlenmeyer flasks after adjustment of the pH of the TT/14 medium to 7.0 and

sterilization at 121 °C for 25 min.

Table 8

Composition of TT/14 Bioconversion Medium

Potato starch 5.0 g

Glucose 25.0 g

Yeast extract (Gistex' 15.0 g soya peptone 15.0 g

CaCO₃ 5.0 g

CoCl₂»6H₂0 2.0 mg

Tap water 1000 ml

The flasks were shaken on a rotary shaker (250 r.p.m., 2.5 cm amplitude) for 3

days. Compactin sodium salt feeding, bioconversion and determination of the pravastatin

content were carried out as described in Example 5. At the end of the bioconversion the pravastatin content of the fermentation broth was 40μg/ml, as measured by HPLC.

Example 8

Inoculation, incubation, fermentation and compactin sodium salt feeding were

carried out with the Micromonospora rosaria IDR-P₇ [NCAIM P (B) 001274] bacterium

strain following the method described in Example 1. At the end of the bioconversion, 350 μg/ml pravastatin was in the fermentation broth, as measured by HPLC.

Having thus described the invention with reference to certain preferred

embodiments and with examples, those skilled in the art will appreciate variations that do not depart from the spirit and scope of the invention as described above and claimed

hereafter.

Claims

WE CLAIM:

A microbial process for the preparation of the compound of formula (I)

(I)

from a compound of the general formula (II)

(II)

wherein R⁺ stands for an alkali metal or ammonium ion, by a strain able to 6β-hydroxylate

a compound of formula (II) by fermentation and by the separation and purification of the compound of formula (I) formed in the course of the bioconversion comprising the steps

of a) cultivating a microorganism of the genus Micromonospora able to 6β- hydroxylate a compound of formula (II), wherein R⁺ is as defined above, on a nutrient medium containing assimilable carbon and nitrogen sources,

thereafter

b) feeding a substrate to be transformed into the developed culture, then

c) fermenting the substrate until the end of bioconversion, then

d) separating the compound of formula (I) from the culture broth and, if

desired, purifying the same.

2. The process of claim 9 wherein the microorganism is cultivated at a temperature

of from about 25 to about 37 °C.

3. The process of claim 10 wherein the microorganism is cultivated at a temperature

of from about 25 to about 32 °C.

4. The process of claim 9 wherein the nutrient medium is an aqueous liquid.

5. The process of claim 9 wherein the nutrient medium further comprises mineral

salts.

6. The process as claimed in Claim 9 wherein the Micromonospora sp. IDR-P₃ strain

deposited at the National Collection of Agricultural and Industrial

Microorganisms, Budapest, Hungary under the number NCAIM P (B) 001268, or

a mutant strain thereof, which is able to 6β-hydroxylate a compound of general

formula (II) is cultivated.

7. The process as claimed in Claim 9 wherein the Micromonospora purpurea IDR-P₄

strain deposited at the National Collection of Agricultural and Industrial

Microorganisms, Budapest, Hungary under the number NCAIM P (B) 001271, or

a mutant strain thereof, which is able to 6β-hydroxylate a compound of general formula (II) is cultivated.

8. The process as claimed in Claim 9 wherein the Micromonospora echinospora ssp.

echinospora IDR-P₅ strain deposited at the National Collection of Agricultural

and Industrial Microorganisms, Budapest, Hungary under the number NCAIM P

(B) 001272, or a mutant strain thereof, which is able to 6β-hydroxylate a

compound of general formula (II) is cultivated.

9. The process as claimed in Claim 9 wherein the Micromonospora megalomicea

ssp. nigra IDR-P₆ strain deposited at the National Collection of Agricultural and

Industrial Microorganisms, Budapest, Hungary under the number NCAIM P (B)

001273, or a mutant strain thereof, which is able to 6β-hydroxylate a compound of

general formula (II) is cultivated.

10. The process as claimed in Claim 9 wherein the Micromonospora rosaria IDR-P₇

strain deposited at the National Collection of Agricultural and Industrial

Microorganisms, Budapest, Hungary under the number NCAIM P (B) 001274, or

a mutant strain thereof, which is able to 6β-hydroxylate a compound of general

formula (II) is cultivated.

11. The process as claimed in Claim 9 wherein R⁺ is a sodium ion.

12. The process as claimed in Claims 9 to 18 wherein the compound of formula (I)

formed during the fermentation is separated from the culture broth by adsorption on an anionic ion exchange resin or by extraction with a water-immiscible organic

solvent, followed by the preparation of its lactone derivative or its secondary

amine salt as an intermediate, or by purification of the alkaline aqueous extract

obtained from the organic solvent extract of the fermentation broth with chromatography on a non-ionic adsorbing resin.