Sono-leather technology with ultrasound: a boon for unit operations in leather processing - review of our research work at Central Leather Research Institute (CLRI), India.

Ultrasound is a sound wave with a frequency above the human audible range of 16 Hz to 16 kHz. In recent years, numerous unit operations involving physical as well as chemical processes are reported to have been enhanced by ultrasonic irradiation. There have been benefits such as improvement in process efficiency, process time reduction, performing the processes under milder conditions and avoiding the use of some toxic chemicals to achieve cleaner processing. These could be a better way of augmentation for the processes as an advanced technique. The important point here is that ultrasonic irradiation is physical method activation rather than using chemical entities. Detailed studies have been made in the unit operations related to leather such as diffusion rate enhancement through porous leather matrix, cleaning, degreasing, tanning, dyeing, fatliquoring, oil-water emulsification process and solid-liquid tannin extraction from vegetable tanning materials as well as in precipitation reaction in wastewater treatment. The fundamental mechanism involved in these processes is ultrasonic cavitation in liquid media. In addition to this there also exist some process specific mechanisms for the enhancement of the processes. For instance, possible real-time reversible pore-size changes during ultrasound propagation through skin/leather matrix could be a reason for diffusion rate enhancement in leather processing as reported for the first time. Exhaustive scientific research work has been carried out in this area by our group working in Chemical Engineering Division of CLRI and most of these benefits have been proven with publications in valued peer-reviewed international journals. The overall results indicate that about 2-5-fold increase in the process efficiency due to ultrasound under the given process conditions for various unit operations with additional benefits. Scale-up studies are underway for converting these concepts in to a real viable larger scale operation. In the present paper, summary of our research findings from employing this technique in various unit operations such as cleaning, diffusion, emulsification, particle-size reduction, solid-liquid leaching (tannin and natural dye extraction) as well as precipitation has been presented.

Effect of UV irradiation on stabilized collagen: role of chromium(III).

Research on the effect of UV radiation on stabilized collagen is an area of potential interest owing to the fact that collagen is an important biomaterial finding immense use in various fields. In this present study, effect of UV irradiation on collagen stabilized using chromium(III) has been studied. The physical and optical properties affected by UV irradiation have been detailed. Viscosity measurements have shown that chromium(III) treated collagen has better stability against UV radiation than native collagen. Circular dichroic studies indicate that increase in concentration of chromium(III) does not affect the conformation of collagen however, the duration of irradiation has profound impact on the conformation of collagen. The fluorescence intensity of native collagen has been found to decrease more than that of chromium(III) treated collagen. The difference absorption spectra also shows that chromium(III) treatment brings about more stability to collagen against UV irradiation.

Progress and recent trends in biotechnological methods for leather processing.

Global environmental regulations are changing the leather-processing industry. Pre-tanning and tanning processes contribute 80-90% of the total pollution in the industry and generate noxious gases, such as hydrogen sulfide, as well as solid wastes, such as lime and chrome sludge. The use of enzyme-based products is currently being explored for many areas of leather making. Furthermore, enzymes are gaining increasing importance in the de-hairing process, eliminating the need for sodium sulfide. This review discusses emerging novel biotechnological methods used in leather processing. One significant achievement is the development of a bioprocess-based de-hairing and fiber-opening methodology to reduce toxic waste.

Apoptosis of lymphocytes induced by chromium(VI/V) is through ROS-mediated activation of Src-family kinases and caspase-3.

Mechanistic insights into Cr(VI)-induced carcinogenicity and possible implication of Cr(V) species formed by the redox reactions of chromium-bearing species have attracted interest. We have previously demonstrated that when human peripheral blood lymphocytes are exposed to the Cr(V) complexes, viz., sodium bis(2-ethyl-2-hydroxybutyrato)oxochromate(V), Na[Cr(V)O(ehba)(2)] and sodium bis(2-hydroxy-2-methylbutyrato)oxochromate(V), Na[Cr(V)O(hmba)(2)], apoptosis and formation of reactive oxygen species (ROS) are observed. The molecular mechanisms involving cellular signaling pathways leading to apoptosis are addressed in the present study. Treatment of lymphocytes with Na[Cr(V)O(ehba)(2)] and K(2)Cr(2)O(7) leads to the activation of the Src-family protein tyrosine kinases namely, p56(lck), p59(fyn), and p56/53(lyn), which then activates caspase-3, both of which are under the partial influence of ROS. Inhibition of the Src-family tyrosine kinases activity by PP2 and of caspase-3 by Z-DEVD-FMK reverses apoptosis, thereby suggesting their importance. Antioxidants only partially reverse the apoptosis induced by Cr(VI/V), suggesting that pathways other than those induced by ROS cannot be ruled out. Although the complex, Na[Cr(V)O(ehba)(2)] is known to be relatively stable in aqueous solutions, previous studies have shown that the Cr(V) complex, Na[Cr(V)O(ehba)(2)] disproportionates to Cr(VI) and Cr(III) forms at pH 7.4 through complex mechanistic processes. Dynamics studies employing EPR data show that the Cr(V) state in Na[Cr(V)O(ehba)(2)] is relatively more stable in RPMI-1640 medium containing plasma. Formation of ROS during the reaction of redox partners with Na[Cr(V)O(ehba)(2)] is an early event and compares favorably in kinetic terms with the reported rate processes for disproportionation. This investigation presents evidence for the direct implication of Cr(V) in Cr(VI)-induced apoptosis of lymphocytes.

Chromium(III)-induced apoptosis of lymphocytes: death decision by ROS and Src-family tyrosine kinases.

Apoptosis is an active process induced by a variety of physiological and external stimuli, in which elimination of damaged cells are effected through a genetically controlled process. In this study, we have examined the mechanism of chromium(III) [Cr(III)]-induced cytotoxicity with respect to its relationship to oxidative stress. Morphology, flow cytometry, and DNA fragmentation studies show that tris-(1,10-phenanthroline)chromium(III) [Cr(III)-phen], tris-(2,2'-bipyridyl)chromium(III) [Cr(III)-bpy], trans-diaqua[1,2-bis(salicylideneamino)ethanechromium(III)] [Cr(III)-salen], and trans-diaqua[1,3-bis(salicylideneamino)propanechromium(III)] [Cr(III)-salprn] induced apoptosis of lymphocytes. Pentaammineaquachromium(III) [Cr(III)-hpa] does not induce apoptosis. Apoptosis induced by these complexes involves the generation of reactive oxygen species (ROS) as seen by increased fluorescence of dichloroflourescein (DCF) observed through flow cytometry. Pretreatment of lymphocytes with antioxidants completely abrogate apoptosis. Cr(III) treatment also increased the expression and activation of Src-family tyrosine kinases viz. p56lck, p59fyn, and p53/56lyn, as seen by immunoblotting and immune complex kinase assay. PP2, a selective Src-family tyrosine kinase inhibitor, abolishes apoptosis, indicating that Src-family tyrosine kinases are directly involved in eliciting apoptosis. Interestingly, a one-to-one correlation between the expression of Src-family tyrosine kinases and ROS is observed, since antioxidants pretreatment inhibits the expression and the activation of these kinases. These results further indicate that Cr(III)-induced apoptosis is mediated through production of ROS, which in turn activates the Src-family tyrosine kinases. The increased activation of Src-family tyrosine kinases may be a mechanism involved in apoptosis of lymphocytes elicited by various other physiological stimuli that exploit ROS as a second messenger.

Interaction of aldehydes with collagen: effect on thermal, enzymatic and conformational stability.

Stabilization of type I rat tail tendon (RTT) collagen by various aldehydes, viz. formaldehyde, gluteraldehyde, glyoxal and crotanaldehyde was studied to understand the effect of each on the thermal, enzymatic and conformational stability of collagen. The aldehydes have been found to increase the heat stability of rat tail tendon collagen fibres from 62 to 77-86 degrees C. The increase in thermal stability was found to be in a species dependent manner. The variation in the thermal stability of collagen brought about by aldehydes was in the order of formaldehyde > gluteraldehyde > glyoxal > crotanaldehdye. The aldehydes also impart a high degree of stability to collagen against the activity of the degrading enzyme, collagenase. The order of enzymatic stability brought about by aldehydes follows the same trend as the thermal stability brought about by them. This shows that the number of cross-links formed influence both the thermal and enzymatic stability in the similar manner. The effect of various aldehydes on the secondary structure of collagen was studied using circular dichroism and it was found that the aldehydes lead to changes in the amplitude of the circular dichroic (CD) spectrum but did not alter the triple helical conformation of collagen. The secondary structure of collagen is not significantly altered on interaction with different aldehydes.

Molecular dynamic simulation studies on the effect of one residue chain staggering on the structure and stability of heterotrimeric collagen-like peptides with interruption.

A systematic molecular dynamics (MD) simulation has been carried out on collagen-like peptides with different combinations of interruptions in the Gly-X(AA) -Y(AA) repeats. Although experimental studies have been carried out to elucidate the structural consequences of homotrimeric collagen-like peptides, this is the first report on the structural effect on the heterotrimeric models with G4G and G1G breaks present simultaneously in the constituent chains with difference in one residue chain staggering. The results reveal that the axial registry of the interrupted region changes significantly from that of conventional triple helical peptide without interruption. Further, results from MD simulations show the formation of a kink in the interrupted region of the triple-helical peptides. The conformational analysis reveals that the interruption in the Gly-X(AA) -Y(AA) pattern in these peptides induces ß-strand conformation in triple helical peptides. The conventional hydrogen bonds in the interrupted triad are affected and new nonconventional H-bonds are formed in the triple helical structure, and as a result interrupted region becomes locally fragile. MM-PBSA calculations on the different systems clearly suggest that the binding affinity varies marginally due to one residue staggering. However, it is found from the structural parameters that hydrogen-bonding pattern differs significantly due to the difference in the staggering of chains.

Use of ultrasound in leather processing industry: effect of sonication on substrate and substances--new insights.

Influence of ultrasound (US) on various unit operations in leather processing has been studied with the aim to improve the process efficiency, quality, reduce process time and achieve near-zero discharge levels in effluent streams as a cleaner option. Effect of US on substrate (skin/leather) matrix as well as substances used in different unit operations have been studied and found to be useful in the processing. Absorption of US energy by leather in process vessel at different distances from US source has been measured and found to be significant. Effect of particle-size of different substances due to sonication indicates positive influence on the diffusion through the matrix. Our experimental results suggest that US effect is better realized for the cases with pronounced diffusion hindrance. Influence of US on bioprocessing of leather has been studied and found beneficial. Attempts have also been made to improve the US aided processing using external aids. Operating US in pulse mode operation could be useful in order to reduce the electrical energy consumption. Use of US has also been studied in the preparation of leather auxiliaries involving mass-transfer resistance. Preliminary cost analysis carried out for ultrasound-assisted leather-dyeing process indicates scale-up possibility. Therefore, US application provide improvement in process efficiency as well as making cleaner production methods feasible. Hence, overall results suggest that use of US in leather industry is imminent and potential viable option in near future.

Reversing the conventional leather processing sequence for cleaner leather production.

Conventional leather processing generally involves a combination of single and multistep processes that employs as well as expels various biological, inorganic, and organic materials. It involves nearly 14-15 steps and discharges a huge amount of pollutants. This is primarily due to the fact that conventional leather processing employs a "do-undo" process logic. In this study, the conventional leather processing steps have been reversed to overcome the problems associated with the conventional method. The charges of the skin matrix and of the chemicals and pH profiles of the process have been judiciously used for reversing the process steps. This reversed process eventually avoids several acidification and basification/neutralization steps used in conventional leather processing. The developed process has been validated through various analyses such as chromium content, shrinkage temperature, softness measurements, scanning electron microscopy, and physical testing of the leathers. Further, the performance of the leathers is shown to be on par with conventionally processed leathers through bulk property evaluation. The process enjoys a significant reduction in COD and TS by 53 and 79%, respectively. Water consumption and discharge is reduced by 65 and 64%, respectively. Also, the process benefits from significant reduction in chemicals, time, power, and cost compared to the conventional process.

Non-enzymatic phosphorylation of bovine serum albumin by Cr(V) complexes: role in Cr(VI)-induced phosphorylation and toxicity.

Evidence for the non-enzymatic phosphorylation of bovine serum albumin (BSA) by sodium bis(2-ethyl-2-hydroxybutyrato)oxochromate(V), Na[CrVO(ehba)2], 1, sodium bis(2-hydroxy-2-methylbutyrato)oxochromate(V), Na[CrVO(hmba)2], 2 and potassium dichromate, K2Cr2O7, 3 in the presence of labeled adenosine-5'-triphosphate (ATP) under conditions of physiological pH is presented. Aggregation and extent of phosphorylation of BSA mediated by 1, 2 or 3 seems to increase with the concentration and time of incubation of the reaction mixture containing all the reactants. The [gamma-32P] label in ATP is incorporated into aggregates of BSA in the in vitro reaction of the protein with ATP in the presence of 1, 2 or 3. Phosphorylation of BSA by ATP in the absence of 1, 2 or 3 is negligible. Addition of EDTA reverses aggregation of protein and liberates partially the incorporated phosphate label. The stoichiometry of phosphorylation is found to be the highest and is equal to 12.25 mol PO4(3-)/mol BSA in the presence of 500 microM of 1, which decreases to 10.56 mol PO4(3-)/mol BSA after EDTA treatment. Resistance to the removal of phosphate label by EDTA increases with increase in time of incubation. Dialysis of phosphorylated BSA reverses the incorporated [gamma-(32)P] label only partially, indicating the formation of covalent links of phosphate groups to BSA. Evidence for the site of phosphorylation in the reaction mediated by 1, 2 or 3 being hydroxyl side groups of tyrosine and serine/threonine residues has been gained. Based on the results, a possibility that 1, 2 and 3 mimic the function of tyrosine and serine/threonine kinases has been invoked.

Caspase-3: its potential involvement in Cr(III)-induced apoptosis of lymphocytes.

In this study, we have examined the role of caspase-3 in apoptosis of lymphocytes induced by the chromium(III) complexes viz. tris-(1,10-phenanthroline)chromium(III) chloride (Cr(III)-phen) and trans-diaqua[1,3-bis(salicylideneamino)propanechromium(III)] perchlorate (Cr(III)-salprn). Evidence for caspase-3 activation and poly(ADP-ribose) polymerase (PARP) cleavage in lymphocytes exposed to Cr(III) complexes is revealed through Western blotting analysis. Blocking the activity of caspase-3 with z-DEVD-fmk, prevents apoptosis as evidenced through [3H]-thymidine incorporation, DNA fragmentation assay and measurement of sub-G1 cells by flow cytometry. Pretreatment of lymphocytes with free radical scavengers completely attenuates the activity of caspase-3 suggesting that reactive oxygen species (ROS) are upstream activators of caspase-3. Preincubation of lymphocytes with PP2, a selective Src-family tyrosine kinase inhibitor, abolishes the activation of caspase-3 indicating that Src-family tyrosine kinases viz. p56lck, p59fyn and p53/56lyn are mediators of caspase-3 activation during Cr(III) exposure. Collectively, our findings support a plausible mechanism in which Cr(III) mediates ROS generation that precedes the up-regulation of p56lck, p59fyn and p53/56lyn which eventually activates caspase-3 to promote apoptotic cell death of lymphocytes. To our knowledge, this is the first report suggesting the importance of Src-family tyrosine kinases for the activation of caspase-3 in metal-induced apoptotic cell death.

Bioaccumulation of chromium from tannery wastewater: an approach for chrome recovery and reuse.

The presence of chromium in the effluent is a major concern for the tanning industry. Currently, chemical precipitation methods are practiced for the removal of chromium from the effluent, but that leads to the formation of chrome-bearing solid wastes. The other membrane separation and ion exchange methods available are unfeasible due to their cost. In this study, the removal of chromium from tannery effluent has been carried out using abundantly available brown seaweed Sargassum wightii. Simulated chrome tanning solution was used for the standardization of experimental trials. Various factors influencing the uptake of chromium, viz., quantity of seaweed, concentrations of chromium, pH of the chrome-bearing wastewater, and duration of treatment, have been studied. Chemical modification of the seaweed through pretreatment with sulfuric acid, magnesium chloride, and calcium chloride showed improved uptake of chromium. Langmuir and Freundlich isotherms have been fitted for various quantities of seaweed. The dynamic method of treatment of protonated seaweed with simulated chrome tanning solution at a pH of 3.5-3.8 for a duration of 6 h gave the maximum uptake of about 83%. A similar uptake has been established for commercial chrome tanning wastewater containing the same concentration of chromium. The Sargassum species exhibited a maximum uptake of 35 mg of chromium per gram of seaweed. Fourier transform infrared spectroscopy, energy-dispersive X-ray analysis, and flame photometry studies have been carried out to understand the mechanistic pathway for the removal of chromium. The potential reuse of chromium-containing seaweed for the preparation of basic chromium sulfate (tanning agent) has been demonstrated.

Zero discharge tanning: a shift from chemical to biocatalytic leather processing.

Beam house processes (Beam house processes generally mean liming-reliming processes, which employ beam.) contribute more than 60% of the total pollution from leather processing. The use of lime and sodium sulfide is of environmental concern (1, 2). Recently, the authors have developed an enzyme-based dehairing assisted with a very low amount of sodium sulfide, which completely avoids the use of lime. However, the dehaired pelt requires opening up of fiber bundles for further processing, where lime is employed to achieve this through osmotic swelling. Huge amounts of lime sludge and total solids are the main drawbacks of lime. An alternative bioprocess, based on alpha-amylase for fiber opening, has been attempted after enzymatic unhairing. This totally eliminates the use of lime in leather processing. This method enables subsequent processes and operations in leather making feasible without a deliming process. A control experiment was run in parallel using conventional liming-reliming processes. It has been found that the extent of opening up of fiber bundles using alpha-amylase is comparable to that of the control. This has been substantiated through scanning electron microscopic, stratigraphic chrome distribution analysis, and softness measurements. Performance of the leathers is shown to be on a par with leathers produced by the conventional process through physical and hand evaluation. Importantly, softness of the leathers is numerically proven to be comparable with that of control. The process also demonstrates reduction in chemical oxygen demand load by 45% and total solids load by 20% compared to the conventional process. The total dry sludge from the beam house processes is brought down from 152 to 8 kg for processing 1 ton of raw hides.

Natural leathers from natural materials: progressing toward a new arena in leather processing.

Globally, the leather industry is currently undergoing radical transformation due to pollution and discharge legislations. Thus, the leather industry is pressurized to look for cleaner options for processing the raw hides and skins. Conventional methods of pre-tanning, tanning and post-tanning processes are known to contribute more than 98% of the total pollution load from the leather processing. The conventional method of the tanning process involves the "do-undo" principle. Furthermore, the conventional methods employed in leather processing subject the skin/ hide to a wide variation in pH (2.8-13.0). This results in the emission of huge amounts of pollution loads such as BOD, COD, TDS, TS, sulfates, chlorides and chromium. In the approach illustrated here, the hair and flesh removal as well as fiber opening have been achieved using biocatalysts at pH 8.0, pickle-free natural tanning employing vegetable tannins, and post-tanning using environmentally friendly chemicals. Hence, this process involves dehairing, fiber opening, and pickle-free natural tanning followed by ecofriendly post-tanning. It has been found that the extent of hair removal and opening up of fiber bundles is comparable to that of conventionally processed leathers. This has been substantiated through scanning electron microscopic analysis and softness measurements. Performance of the leathers is shown to be on par with conventionally chrome-tanned leathers through physical and hand evaluation. The process also exhibits zero metal (chromium) discharge and significant reduction in BOD, COD, TDS, and TS loads by 83, 69, 96, and 96%, respectively. Furthermore, the developed process seems to be economically viable.

Biointervention makes leather processing greener: an integrated cleansing and tanning system.

The do-undo methods adopted in conventional leather processing generate huge amounts of pollutants. In other words, conventional methods employed in leather processing subject the skin/hide to wide variations in pH. Pretanning and tanning processes alone contribute more than 90% of the total pollution from leather processing. Included in this is a great deal of solid wastes such as lime and chrome sludge. In the approach described here, the hair and flesh removal as well as fiber opening have been achieved using biocatalysts at pH 8.0 for cow hides. This was followed by a pickle-free chrome tanning, which does not require a basification step. Hence, this tanning technique involves primarily three steps, namely, dehairing, fiber opening, and tanning. It has been found that the extent of hair removal, opening up of fiber bundles, and penetration and distribution of chromium are comparable to that produced by traditional methods. This has been substantiated through scanning electron microscopic, stratigraphic chrome distribution analysis, and softness measurements. Performance of the leathers is shown to be on par with conventionally processed leathers through physical and hand evaluation. Importantly, softness of the leathers is numerically proven to be comparable with that of control. The process also demonstrates reduction in chemical oxygen demand load by 80%, total solids load by 85%, and chromium load by 80% as compared to the conventional process, thereby leading toward zero discharge. The input-output audit shows that the biocatalytic three-step tanning process employs a very low amount of chemicals, thereby reducing the discharge by 90% as compared to the conventional multistep processing. Furthermore, it is also demonstrated that the process is technoeconomically viable.