Optimization and scale-up of α-amylase production by Aspergillus oryzae using solid-state fermentation of edible oil cakes.

BACKGROUND: Amylases produced by fungi during solid-state fermentation are the most widely used commercial enzymes to meet the ever-increasing demands of the global enzyme market. The use of low-cost substrates to curtail the production cost and reuse solid wastes are seen as viable options for the commercial production of many enzymes. Applications of α-amylases in food, feed, and industrial sectors have increased over the years. Additionally, the demand for processed and ready-to-eat food has increased because of the rapid growth of food-processing industries in developing economies. These factors significantly contribute to the global enzyme market. It is estimated that by the end of 2024, the global α-amylase market would reach USD 320.1 million (Grand View Research Inc., 2016). We produced α-amylase using Aspergillus oryzae and low-cost substrates obtained from edible oil cake, such as groundnut oil cake (GOC), coconut oil cake (COC), sesame oil cake (SOC) by solid-state fermentation. We cultivated the fungus using these nutrient-rich substrates to produce the enzyme. The enzyme was extracted, partially purified, and tested for pH and temperature stability. The effect of pH, incubation period and temperature on α-amylase production using A. oryzae was optimized. Box-Behnken design (BBD) of response surface methodology (RSM) was used to optimize and determine the effects of all process parameters on α-amylase production. The overall cost economics of α-amylase production using a pilot-scale fermenter was also studied. RESULTS: The substrate optimization for α-amylase production by the Box-Behnken design of RSM showed GOC as the most suitable substrate for A. oryzae, as evident from its maximum α-amylase production of 9868.12 U/gds. Further optimization of process parameters showed that the initial moisture content of 64%, pH of 4.5, incubation period of 108 h, and temperature of 32.5 °C are optimum conditions for α-amylase production. The production increased by 11.4% (10,994.74 U/gds) by up-scaling and using optimized conditions in a pilot-scale fermenter. The partially purified α-amylase exhibited maximum stability at a pH of 6.0 and a temperature of 55 °C. The overall cost economic studies showed that the partially purified α-amylase could be produced at the rate of Rs. 622/L. CONCLUSIONS: The process parameters for enhanced α-amylase secretion were analyzed using 3D contour plots by RSM, which showed that contour lines were more oriented toward incubation temperature and pH, having a significant effect (p < 0.05) on the α-amylase activity. The optimized parameters were subsequently employed in a 600 L-pilot-scale fermenter for the α-amylase production. The substrates were rich in nutrients, and supplementation of nutrients was not required. Thus, we have suggested an economically viable process of α-amylase production using a pilot-scale fermenter.

Exploration of applying growth-promotion bacteria of Chlorella sorokiniana to open cultivation systems.

Nowadays, artificial construction of bacteria-algae consortia to enhance microalgal biomass is prevalent in enclosed systems, while few are built in an open culture. In this study, Achromobacter sp. and Rhizobium sp., isolated from an open pond of Chlorella sorokiniana, were the microalgal growth-promotion bacteria and selected to build the bacteria-algae consortia with axenic C. sorokiniana in open cultivation systems. To examine the performance of these two artificial bacteria-algae consortia in open culture under stable cultivation conditions, the co-cultivation experiments were conducted under constant temperature and light intensity indoors. It was found that Achromobacter sp. gradually lost the dominance of the population in the co-culture and failed to promote the growth of C. sorokiniana during open cultivation. However, the Rhizobium sp. maintained its dominant population of bacterial community in open culture and could promote the growth of C. sorokiniana, with an enhancement of 13.76%. To further evaluate the effects of Rhizobium sp. on microalgae under variations of temperature and sunlight intensity conditions, the open co-cultivation experiments were built outdoors. Results showed that the growth of C. sorokiniana could rise 13.29% only when Rhizobium sp. was added to the culture continuously, and addition of bacterial solution in log-phase of microalgae could help Rhizobium sp. dominate in the bacterial community. In this way, addition of Rhizobium sp. in the log-phase of C. sorokiniana should be an effective process to be applied to open ponds cultivation. Our findings are a step toward applying growth-promotion bacteria for C. sorokiniana for applications in open cultivation systems.

Analysis of the difference between aged and degenerated pit mud microbiome in fermentation cellars for Chinese Luzhou-flavor baijiu by metatranscriptomics.

BACKGROUD: Chinese Luzhou-flavor baijiu (LFB) was fermented in an underground cellar, and the bottom and side of the cellar were covered with pit muds (PMs), where the metabolic activity of the microorganisms had a significant effect on the LFB quality. PMs can be divided into aged pit mud (AP) and degenerated pit mud (DP), thus, the qualities of LFB generated from AP and DP were different. In this essay, metatranscriptomics method was applied to illustrate the differences of the two PMs, as well as to search out the pivotal microorganisms and genes influencing the quality of LFB. RESULTS: Archaea, Clostridium and some thermophilic microorganisms might bring significant effect in AP, while the active eukaryota and Anaeromyxobacter would cause degeneration in PM. Also, the metabolism of carbohydrate and amino acid were more active in AP. What is more, carbohydrate, amino acid and their derivant can produce important organic acids via the activity of the microorganisms in PMs. There were eight critical enzymes noticed in the organic acids metabolic pathway, which were more actively expressed in AP, demonstrating active expression of the critical genes related to organic acid metabolism could have a positive effect on LFB quality. CONCLUSION: This study identified specific differences in active microorganisms, active expressed genes and the expression levels of key genes in vital metabolic pathway between AP and DP. Which may be the actual reason for the differences in the quality of LFB made from different PMs. Mastering these results will provide assistance to improve the quality of LFB. © 2021 Society of Chemical Industry.

Improvement of cadaverine production in whole cell system with baker's yeast for cofactor regeneration.

Cadaverine, 1,5-diaminopentane, is one of the most promising chemicals for biobased-polyamide production and it has been successfully produced up to molar concentration. Pyridoxal 5'-phosphate (PLP) is a critical cofactor for inducible lysine decarboxylase (CadA) and is required up to micromolar concentration level. Previously the regeneration of PLP in cadaverine bioconversion has been studied and salvage pathway pyridoxal kinase (PdxY) was successfully introduced; however, this system also required a continuous supply of adenosine 5'-triphosphate (ATP) for PLP regeneration from pyridoxal (PL) which add in cost. Herein, to improve the process further a method of ATP regeneration was established by applying baker's yeast with jhAY strain harboring CadA and PdxY, and demonstrated that providing a moderate amount of adenosine 5'-triphosphate (ATP) with the simple addition of baker's yeast could increase cadaverine production dramatically. After optimization of reaction conditions, such as PL, adenosine 5'-diphosphate, MgCl2, and phosphate buffer, we able to achieve high production (1740 mM, 87% yield) from 2 M L-lysine. Moreover, this approach could give averaged 80.4% of cadaverine yield after three times reactions with baker's yeast and jhAY strain. It is expected that baker's yeast could be applied to other reactions requiring an ATP regeneration system.

Model-assisted DoE software: optimization of growth and biocatalysis in Saccharomyces cerevisiae bioprocesses.

Bioprocess development and optimization are still cost- and time-intensive due to the enormous number of experiments involved. In this study, the recently introduced model-assisted Design of Experiments (mDoE) concept (Möller et al. in Bioproc Biosyst Eng 42(5):867, https://doi.org/10.1007/s00449-019-02089-7 , 2019) was extended and implemented into a software ("mDoE-toolbox") to significantly reduce the number of required cultivations. The application of the toolbox is exemplary shown in two case studies with Saccharomyces cerevisiae. In the first case study, a fed-batch process was optimized with respect to the pH value and linearly rising feeding rates of glucose and nitrogen source. Using the mDoE-toolbox, the biomass concentration was increased by 30% compared to previously performed experiments. The second case study was the whole-cell biocatalysis of ethyl acetoacetate (EAA) to (S)-ethyl-3-hydroxybutyrate (E3HB), for which the feeding rates of glucose, nitrogen source, and EAA were optimized. An increase of 80% compared to a previously performed experiment with similar initial conditions was achieved for the E3HB concentration.

Dynamic parameter estimation and prediction over consecutive scales, based on moving horizon estimation: applied to an industrial cell culture seed train.

Bioprocess modeling has become a useful tool for prediction of the process future with the aim to deduce operating decisions (e.g. transfer or feeds). Due to variabilities, which often occur between and within batches, updating (re-estimation) of model parameters is required at certain time intervals (dynamic parameter estimation) to obtain reliable predictions. This can be challenging in the presence of low sampling frequencies (e.g. every 24 h), different consecutive scales and large measurement errors, as in the case of cell culture seed trains. This contribution presents an iterative learning workflow which generates and incorporates knowledge concerning cell growth during the process by using a moving horizon estimation (MHE) approach for updating of model parameters. This estimation technique is compared to a classical weighted least squares estimation (WLSE) approach in the context of model updating over three consecutive cultivation scales (40-2160 L) of an industrial cell culture seed train. Both techniques were investigated regarding robustness concerning the aforementioned challenges and the required amount of experimental data (estimation horizon). It is shown how the proposed MHE can deal with the aforementioned difficulties by the integration of prior knowledge, even if only data at two sampling points are available, outperforming the classical WLSE approach. This workflow allows to adequately integrate current process behavior into the model and can therefore be a suitable component of a digital twin.

The impact of clearance on mixing time for interface-added substrate.

This study was carried out to find the optimum clearance (impeller to bottom distance) for Rushton and pitch-blade turbine impellers in a stirred tank bioreactor for improved substrate mixing time added at interface, taking advantage of computational fluid dynamics. In this regard, the time needed for a thin layer of liquid, resembling substrate-rich or poor part, getting homogenously dispersed within the tank was calculated. The mixing time calculated in this way is called the surface aeration related mixing time (SARMT). SARMT was calculated using two approaches and was compared with each other. For the pitch-blade turbine impeller, a criterion which guarantees accurate mixing time by simulation was not satisfied, so the SARMT profile against clearance was not achieved. For the Rushton impeller, a general descending order of SARMT against impeller-bottom clearance was observed.

[Numerical simulation and optimization of impeller combination used in stirred bioreactor].

Bioreactors have been central in monoclonal antibodies and vaccines manufacturing by mammalian cells in suspension culture. Numerical simulation of five impeller combinations in a stirred bioreactor was conducted, and characteristics of velocity vectors, distributions of gas hold-up, distributions of shear rate in the bioreactor using 5 impeller combinations were numerically elucidated. In addition, genetically engineered CHO cells were cultivated in bioreactor installed with 5 different impeller combinations in fed-batch culture mode. The cell growth and antibody level were directly related to the maximum shear rate in the bioreactor, and the highest viable cell density and the peak antibody level were achieved in FBMI3 impeller combination, indicating that CHO cells are sensitive to shear force produced by impeller movement when cells were cultivated in bioreactor at large scale, and the maximum shear rate would play key roles in scaling-up of bioreactor at industrial scale.

Downscaling screening cultures in a multifunctional bioreactor array-on-a-chip for speeding up optimization of yeast-based lactic acid bioproduction.

A key challenge for bioprocess engineering is the identification of the optimum process conditions for the production of biochemical and biopharmaceutical compounds using prokaryotic as well as eukaryotic cell factories. Shake flasks and bench-scale bioreactor systems are still the golden standard in the early stage of bioprocess development, though they are known to be expensive, time-consuming, and labor-intensive as well as lacking the throughput for efficient production optimizations. To bridge the technological gap between bioprocess optimization and upscaling, we have developed a microfluidic bioreactor array to reduce time and costs, and to increase throughput compared with traditional lab-scale culture strategies. We present a multifunctional microfluidic device containing 12 individual bioreactors (Vt = 15 µl) in a 26 mm × 76 mm area with in-line biosensing of dissolved oxygen and biomass concentration. Following initial device characterization, the bioreactor lab-on-a-chip was used in a proof-of-principle study to identify the most productive cell line for lactic acid production out of two engineered yeast strains, evaluating whether it could reduce the time needed for collecting meaningful data compared with shake flasks cultures. Results of the study showed significant difference in the strains' productivity within 3 hr of operation exhibiting a 4- to 6-fold higher lactic acid production, thus pointing at the potential of microfluidic technology as effective screening tool for fast and parallelizable industrial bioprocess development.

An overview of cell disruption methods for intracellular biomolecules recovery.

Bacteria, yeast, and microalgae are sources of biomolecules such as enzymes, lipids, pigments, organic acids and, proteins for industrial application. These high-added-value biomolecules are often intracellularly bioaccumulated, and their recovery involves several downstream processes, in which the most crucial stage is the disruption of the cell wall. The choice of the method influences the further downstream steps and, consequently, its complexity and cost. In this review, severe and gentle methods currently used for disruption or permeabilization of bacteria, yeast, and microalgae were discussed based on their principle, application, and feasibility. Also, recent studies regarding the microbial cell disruption were presented in order to facilitate the choice of the more effective method. Some factors such as cell wall composition, nature of biomolecule, purity degree, scalability, and energy input are necessary to be considered on selecting the most appropriate disruption method. The severe methods, such as high pressure-homogenization, and ultrasonication present higher yield, lower cost, and feasibility to scale-up when compared to the gentle methods. However, in order to achieve a higher recovery yield, further studies must focus on the optimization of operational parameters and on the combination of severe and gentle methods.

A robust flow cytometry-based biomass monitoring tool enables rapid at-line characterization of S. cerevisiae physiology during continuous bioprocessing of spent sulfite liquor.

Assessment of viable biomass is challenging in bioprocesses involving complex media with distinct biomass and media particle populations. Biomass monitoring in these circumstances usually requires elaborate offline methods or sophisticated inline sensors. Reliable monitoring tools in an at-line capacity represent a promising alternative but are still scarce to date. In this study, a flow cytometry-based method for biomass monitoring in spent sulfite liquor medium as feedstock for second generation bioethanol production with yeast was developed. The method is capable of (i) yeast cell quantification against medium background, (ii) determination of yeast viability, and (iii) assessment of yeast physiology though morphological analysis of the budding division process. Thus, enhanced insight into physiology and morphology is provided which is not accessible through common online and offline biomass monitoring methods. To demonstrate the capabilities of this method, firstly, a continuous ethanol fermentation process of Saccharomyces cerevisiae with filtered and unfiltered spent sulfite liquor media was analyzed. Subsequently, at-line process monitoring of viability in a retentostat cultivation was conducted. The obtained information was used for a simple control based on addition of essential nutrients in relation to viability. Thereby, inter-dependencies between nutrient supply, physiology, and specific ethanol productivity that are essential for process design could be illuminated. Graphical abstract.

Ectoine production with indigenous Marinococcus sp. MAR2 isolated from the marine environment.

Ectoine has fostered the development of products for skin care and cosmetics. In this study, we employed the marine bacterial strain Marinococcus sp. MAR2 to increase ectoine production by optimizing medium constituents using Response Surface Methodology (RSM) and a fed-batch strategy. The results from the steepest ascent and central composite design indicated that 54 g/L of yeast extract, 14.0 g/L of ammonium acetate, 74.4 g/L of sodium glutamate, and 6.2 g/L of sodium citrate constituted the optimal medium with maximum ectoine production (3.5 g/L). In addition, we performed fed-batch culture in the bioreactor, combining pH and dissolved oxygen to produce ectoine by Marinococcus sp. MAR2. The ectoine production, content, and productivity of 5.6 g/L, 10%, and 3.9 g/L/day were further reached by a fed-batch culture. Thus, the ectoine production by Marinococcus sp. MAR2 using RSM and fed-batch strategy shows its potential for industrial production.

Increased torulene production by the red yeast, Sporidiobolus pararoseus, using citrus juice.

Response surface methodology was applied to maximize the yield and production of carotenoids by Sporidiobolus pararoseus WZ012 using citrus juice. A high concentration of yeast extract and citrus juice favored carotenoid production and biomass concentration, respectively. Under optimal conditions, a more than 51 percent (from 860 to 1300 µg/g) and 62 percent (from 17.05 to 27.66 mg/L) respective enhancement in intracellular and total carotenoid production was achieved. Finally, this process was successfully upscaled in a 5-L fermentor. A comparison of the carotenoid distributions revealed that torulene (61.3%) was the dominant carotenoid when using the citrus based medium, while the main carotenoid was ß-carotene (62.5%) when using the glucose medium. The present work provides an alternative method to produce high-value products derived from waste and low-grade citrus.

Variations in microbial community structure and functional gene expression in bio-treatment processes with odorous pollutants.

Engineered microbial ecosystems in biofilters have been widely applied to treat odorous gases from industrial emissions. Variations in microbial community structure and function associated with the removal of odorous gases by biofilters are largely unknown. This study performed a metagenomic analysis to discover shifts in microbial community structures in a commercial scale biofilter after treating odorous gas. Our study identified 175,675 functional genes assigned into 43 functional KEGG pathways. Based on the unigene sequences, there were significant changes in microbial community structures in the biofilter after treating odorous gas. The dominant genera were Thiobacillus and Oceanicaulis before the treatment, and were Acidithiobacillus and Ferroplasma after the treatment. A clustering analysis showed that the number of down-regulated microbes exceeded the number of up-regulated microbes, suggesting that odorous gas treatment reduced in microbial community structures. A differential expression analysis identified 29,975 up- and 452,599 down-regulated genes. An enrichment analysis showed 17 classic types of xenobiotic biodegradation pathways. The results identified 16 and 15 genes involved in ammonia and sulfite metabolism, respectively; an analysis of their relative abundance identified several up-regulated genes, which may be efficient genes involved in removing odorous gases. The data provided in this study demonstrate the changes in microbial communities and help identify the dominant microflora and genes that play key roles in treating odorous gases.

Heterotrophy as a tool to overcome the long and costly autotrophic scale-up process for large scale production of microalgae.

Industrial scale-up of microalgal cultures is often a protracted step prone to culture collapse and the occurrence of unwanted contaminants. To solve this problem, a two-stage scale-up process was developed - heterotrophically Chlorella vulgaris cells grown in fermenters (1st stage) were used to directly inoculate an outdoor industrial autotrophic microalgal production unit (2nd stage). A preliminary pilot-scale trial revealed that C. vulgaris cells grown heterotrophically adapted readily to outdoor autotrophic growth conditions (1-m3 photobioreactors) without any measurable difference as compared to conventional autotrophic inocula. Biomass concentration of 174.5 g L-1, the highest value ever reported for this microalga, was achieved in a 5-L fermenter during scale-up using the heterotrophic route. Inocula grown in 0.2- and 5-m3 industrial fermenters with mean productivity of 27.54 ± 5.07 and 31.86 ± 2.87 g L-1 d-1, respectively, were later used to seed several outdoor 100-m3 tubular photobioreactors. Overall, all photobioreactor cultures seeded from the heterotrophic route reached standard protein and chlorophyll contents of 52.18 ± 1.30% of DW and 23.98 ± 1.57 mg g-1 DW, respectively. In addition to providing reproducible, high-quality inocula, this two-stage approach led to a 5-fold and 12-fold decrease in scale-up time and occupancy area used for industrial scale-up, respectively.

Screening for Oily Yeasts Able to Convert Hydrolysates from Biomass to Biofuels While Maintaining Industrial Process Relevance.

Research has recently intensified to discover new oleaginous yeast strains able to function quickly and efficiently in low-cost lignocellulosic hydrolysates to produce high-quality lipids for use in biodiesel and chemicals. Detailed techniques are given here for ranking candidate yeast strains based on conversion of hydrolysate sugars to lipids and then optimizing cultivation conditions for best performers in a 96-well aerobic microcultivation format. A full battery of assays applicable to high throughput of small-volume samples are described for efficiently evaluating cell biomass production, lipid accumulation, fatty acid composition, and sugar utilization. Original data is additionally presented on the validation of the microtechnique for GC analysis of lipid composition in yeast since this application involved modification of a previously published assay for microalgae.

Astin C Production by the Endophytic Fungus Cyanodermella asteris in Planktonic and Immobilized Culture Conditions.

The fungal endophyte Cyanodermella asteris (C. asteris) has been recently isolated from the medicinal plant Aster tataricus (A. tataricus). This fungus produces astin C, a cyclic pentapeptide with anticancer and anti-inflammatory properties. The production of this secondary metabolite is compared in immobilized and planktonic conditions. For immobilized cultures, a stainless steel packing immersed in the culture broth is used as a support. In these conditions, the fungus exclusively grows on the packing, which provides a considerable advantage for astin C recovery and purification. C. asteris metabolism is different according to the culture conditions in terms of substrate consumption rate, cell growth, and astin C production. Immobilized-cell cultures yield a 30% increase of astin C production, associated with a 39% increase in biomass. The inoculum type as spores rather than hyphae, and a pre-inoculation washing procedure with sodium hydroxide, turns out to be beneficial both for astin C production and fungus development onto the support. Finally, the influence of culture parameters such as pH and medium composition on astin C production is evaluated. With optimized culture conditions, astin C yield is further improved reaching a five times higher final specific yield compared to the value reported with astin C extraction from A. tataricus (0.89 mg g-1 and 0.16 mg g-1 respectively).

Design and Operation of a Pilot-Scale Packed-Bed Bioreactor for the Production of Enzymes by Solid-State Fermentation.

In this review, we describe our experience in building a pilot-scale packed-bed solid-state fermentation (SSF) bioreactor, with provision for intermittent mixing, and the use of this bioreactor to produce pectinases and lipases by filamentous fungi. We show that, at pilot scale, special attention must be given to several aspects that are not usually problematic when one works with laboratory-scale SSF bioreactors. For example, it can be a challenge to produce large amounts of inoculum if the fungus does not sporulate well. Likewise, at larger scales, the air preparation system needs as much attention as the bioreactor itself. Sampling can also be problematic if one wishes to avoid disrupting the bed structure. In the fermentations carried out in the pilot bioreactor, when the substrate bed contained predominantly wheat bran, the bed shrank away from the walls, providing preferential flow paths for the air and necessitating agitation of the bed. These problems were avoided by using beds with approximately 50% of sugarcane bagasse. We also show how a mathematical model that describes heat and water transfer in the bed can be a useful tool in developing appropriate control schemes. Graphical Abstract.

Recent developments in bioreactor scale production of bacterial polyhydroxyalkanoates.

Polyhydroxyalkanoates (PHAs) are biological plastics that are sustainable alternative to synthetic ones. Numerous microorganisms have been identified as PHAs producers. They store PHAs as cellular inclusions to use as an energy source backup. They can be produced in shake flasks and in bioreactors under defined fermentation and physiological culture conditions using suitable nutrients. Their production at bioreactor scale depends on various factors such as carbon source, nutrients supply, temperature, dissolved oxygen level, pH, and production modes. Once produced, PHAs find diverse applications in multiple fields of science and technology particularly in the medical sector. The present review covers some recent developments in sustainable bioreactor scale production of PHAs and identifies some areas in which future research in this field might be focused.