Challenges and opportunities in lactic acid bioprocess design—From economic to production aspects

In vivo evolution of lactic acid hyper-tolerant Clostridium thermocellum

Lactic acid (LA) has several applications in the food, cosmetics and pharmaceutical industries, as well as in the production of biodegradable plastic polymers, namely polylactides. Industrial production of LA is essentially based on microbial fermentation. Recent reports have shown the potential of the cellulolytic bacterium Clostridium thermocellum for direct LA production from inexpensive lignocellulosic biomass. However, C. thermocellum is highly sensitive to acids and does not grow at pH < 6.0. Improvement of LA tolerance of this microorganism is pivotal for its application in cost-efficient production of LA. In the present study, the LA tolerance of C. thermocellum strains LL345 (wild-type fermentation profile) and LL1111 (high LA yield) was increased by adaptive laboratory evolution. At large inoculum size (10 %), the maximum tolerated LA concentration of strain LL1111 was more than doubled, from 15 g/L to 35 g/L, while subcultures evolved from LL345 showed 50-85 % faster growth in medium containing 45 g/L LA. Gene mutations (pyruvate phosphate dikinase, histidine protein kinase/phosphorylase) possibly affecting carbohydrate and/or phosphate metabolism have been detected in most LA-adapted populations. Although improvement of LA tolerance may sometimes also enable higher LA production in microorganisms, C. thermocellum LA-adapted cultures showed a yield of LA, and generally of other organic acids, similar to or lower than parental strains. Based on its improved LA tolerance and LA titer similar to its parent strain (LL1111), mixed adapted culture LL1630 showed the highest performing phenotype and could serve as a framework for improving LA production by further metabolic engineering.

Two-species community design of lactic acid bacteria for optimal production of lactate

Microbial communities that metabolise pentose and hexose sugars are useful in producing high-value chemicals, resulting in the effective conversion of raw materials to the product, a reduction in the production cost, and increased yield. Here, we present a computational analysis approach called CAMP (Co-culture/Community Analyses for Metabolite Production) that simulates and identifies appropriate communities to produce a metabolite of interest. To demonstrate this approach, we focus on the optimal production of lactate from various Lactic Acid Bacteria. We used genome-scale metabolic models (GSMMs) belonging to Lactobacillus, Leuconostoc, and Pediococcus species from the Virtual Metabolic Human (VMH; https://vmh.life/) resource and well-curated GSMMs of L. plantarum WCSF1 and L. reuteri JCM 1112. We analysed 1176 two-species communities using a constraint-based modelling method for steady-state flux-balance analysis of communities. Flux variability analysis was used to detect the maximum lactate flux in the communities. Using glucose or xylose as substrates separately or in combination resulted in either parasitism, amensalism, or mutualism being the dominant interaction behaviour in the communities. Interaction behaviour between members of the community was deduced based on variations in the predicted growth rates of monocultures and co-cultures. Acetaldehyde, ethanol, acetate, among other metabolites, were found to be cross-fed between community members. L. plantarum WCSF1 was found to be a member of communities with high lactate yields. In silico community optimisation strategies to predict reaction knock-outs for improving lactate flux were implemented. Reaction knock-outs of acetate kinase, phosphate acetyltransferase, and fumarate reductase in the communities were found to enhance lactate production.

Valorization of municipal organic waste into purified lactic acid

Municipal organic waste (biowaste) consists of food derived starch, protein and sugars, and lignocellulose derived cellulose, hemicellulose, lignin and pectin. Proper management enables nutrient recycling and sustainable production of platform chemicals such as lactic acid (LA). This review gathers the most important information regarding use of biowaste for LA fermentation covering pre-treatment, enzymatic hydrolysis, fermentation and downstream processing to achieve high purity LA. The optimal approach was found to treat the two biowaste fractions separately due to different pre-treatment and enzyme needs for achieving enzymatic hydrolysis and to do continues fermentation to achieve high cell density and high LA productivity up to 12 g/L/h for production of both L and D isomers. The specific productivity was 0.4 to 0.5 h^-1 but with recalcitrant biomass, the enzymatic hydrolysis was rate limiting. Novel purification approaches included reactive distillation and emulsion liquid membrane separation yielding purities sufficient for polylactic acid production.

Third-generation L-Lactic acid production by the microwave-assisted hydrolysis of red macroalgae Eucheuma denticulatum extract

The development of an efficient third-generation L-lactic acid (L-LA) production process from Eucheuma denticulatum extract (EDE) was achieved in this study. Microwave-assisted dilute acid hydrolysis (MADAH) and microwave-assisted hydrothermal hydrolysis (MAHTH) were chosen as the hydrolysis of EDE for the objective of increasing galactose yield. Single-factor optimization of hydrolysis of the EDE was studied, MADAH had high performance in galactose production relative to MAHTH, in which the yield and optimal conditions for both processes were 50.7% (0.1 M H₂SO₄, 120 °C for 25 min) and 47.8% (0 M H₂SO₄,160 °C for 35 min), respectively. For fermentation, the optimal L-LA yield was achieved at the inoculum cell density of 4% (w/w) Bacillus coagulans ATCC 7050 with 89.4% and 6% (w/w) Lactobacillus acidophilus LA-14 with 87.6%. In addition, lipid-extracted Chlorella vulgaris residues (CVRs) as co-nutrient supplementation increased the relative abundance of B. coagulans ATCC 7050, thus benefiting L-LA production.

Current Progress in Production of Building-Block Organic Acids by Consolidated Bioprocessing of Lignocellulose

Several organic acids have been indicated among the top value chemicals from biomass. Lignocellulose is among the most attractive feedstocks for biorefining processes owing to its high abundance and low cost. However, its highly complex nature and recalcitrance to biodegradation hinder development of cost-competitive fermentation processes. Here, current progress in development of single-pot fermentation (i.e., consolidated bioprocessing, CBP) of lignocellulosic biomass to high value organic acids will be examined, based on the potential of this approach to dramatically reduce process costs. Different strategies for CBP development will be considered such as: (i) design of microbial consortia consisting of (hemi)cellulolytic and valuable-compound producing strains; (ii) engineering of microorganisms that combine biomass-degrading and high-value compound-producing properties in a single strain. The present review will mainly focus on production of organic acids with application as building block chemicals (e.g., adipic, cis,cis-muconic, fumaric, itaconic, lactic, malic, and succinic acid) since polymer synthesis constitutes the largest sector in the chemical industry. Current research advances will be illustrated together with challenges and perspectives for future investigations. In addition, attention will be dedicated to development of acid tolerant microorganisms, an essential feature for improving titer and productivity of fermentative production of acids.

Bioenergy from dairy manure: technologies, challenges and opportunities

Dairy manure (DM) is a kind of cheap cellulosic biomass resource which includes lignocellulose and mineral nutrients. Random stacks not only leads damage to the environment, but also results in waste of natural resources. The traditional ways to use DM include returning it to the soil or acting as a fertilizer, which could reduce environmental pollution to some extent. However, the resource utilization rate is not high and socio-economic performance is not utilized. To expand the application of DM, more and more attention has been paid to explore its potential as bioenergy or bio-chemicals production. This article presented a comprehensive review of different types of bioenergy production from DM and provided a general overview for bioenergy production. Importantly, this paper discussed potentials of DM as candidate feedstocks not only for biogas, bioethanol, biohydrogen, microbial fuel cell, lactic acid, and fumaric acid production by microbial technology, but also for bio-oil and biochar production through apyrolysis process. Additionally, the use of manure for replacing freshwater or nutrients for algae cultivation and cellulase production were also discussed. Overall, DM could be a novel suitable material for future biorefinery. Importantly, considerable efforts and further extensive research on overcoming technical bottlenecks like pretreatment, the effective release of fermentable sugars, the absence of robust organisms for fermentation, energy balance, and life cycle assessment should be needed to develop a comprehensive biorefinery model.

Recent Advances in Lactic Acid Production by Lactic Acid Bacteria

Lactic acid can synthesize high value-added chemicals such as poly lactic acid. In order to further minimize the cost of lactic acid production, some effective strategies (e.g., effective mutagenesis and metabolic engineering) have been applied to increase productive capacity of lactic acid bacteria. In addition, low-cost cheap raw materials (e.g., cheap carbon source and cheap nitrogen source) are also used to reduce the cost of lactic acid production. In this review, we summarized the recent developments in lactic acid production, including efficient strain modification technology (high-efficiency mutagenesis means, adaptive laboratory evolution, and metabolic engineering), the use of low-cost cheap raw materials, and also discussed the future prospects of this field, which could promote the development of lactic acid industry.

Opuntia ficus indica waste as a cost effective carbon source for lactic acid production by Lactobacillus plantarum

Opuntia ficus indica (OFI) waste was evaluated as a fermentation feedstock for lactic acid production using Lactobacillus plantarum. Dilute acid pretreatment of the OFI cladodes (OFIC) was performed for extracting maximum fermentable sugars by optimizing process parameters using statistical optimization method. The best results were obtained with HCl 1% (v/v), temperature 120 °C, residence time 40 min, granulation 350 µm and substrate loading 5% (w/v), the sugar concentration reached 24 g/L with low concentration of hydroxymethylfurfural. The feasibility of producing lactic acid from OFI fruit peel (OFIFP) as a source of carbon was also investigated. Lactobacillus plantarum was shown to have a capacity for lactic acid production from OFIC₃₅₀ (granulation 350 µm) hydrolysate and OFIFP extract without detoxification. The highest lactic acid yields of 0.46 and 0.78 g/g were obtained from enzymatic hydrolysate of pretreated OFIC₃₅₀ and OFIFP extract, respectively.

Lactic acid production by Carnobacterium sp. isolated from a maritime Antarctic lake using eucalyptus enzymatic hydrolysate

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Eucalyptus enzymatic hydrolysate contained mixture of glucose and xylose sugars.

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Carnobacterium sp. produced lactic acid from eucalyptus enzymatic hydrolysate.

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Glucose was consumed faster and completely rather than xylose during fermentation.

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Fed-batch fermentation improved lactic acid production and reached 30 g/L.

Carnobacterium sp., a lactic acid bacterium isolated from a maritime Antarctic lake, was evaluated for lactic acid production from a lignocellulosic hydrolysate. Eucalyptus sawdust, a residue from pulp and paper industries, was subjected to alkaline pretreatment to enhance its enzymatic hydrolysis. Fermentations were performed without and with pH control using eucalyptus enzymatic hydrolysate containing a mixture of glucose and xylose sugars. The sugars were successfully converted into lactic acid in 24 h, resulting in 7.6 g/L of lactic acid and a product yield of 0.50 g/g for pH controlled at 6.5. Fed-batch fermentation performed at a controlled pH of 6.5 improved both the lactic acid production (30 g/L) and the biomass growth (4.2 g/L). l-lactic acid optical purity higher than 95 % was obtained. These results demonstrated the potential usage of Carnobacterium sp in l-lactic acid production from eucalyptus.

Valorisation of fungal hydrolysates of exhausted sugar beet pulp for lactic acid production

BACKGROUND

Exhausted sugar beet pulp pellets (ESBPP) were used as raw material for lactic acid (LA) fermentation. The enzymatic hydrolysis of ESBPP was performed with the solid obtained after the fungal solid-state fermentation of ESBPP as a source of hydrolytic enzymes. Subsequently, a medium rich in glucose and arabinose was obtained, which was used to produce LA by fermentation. For LA production, two Lactobacillus strains were assayed and the effects of the supplementation of the hydrolysate with a nitrogen source and the mode of pH regulation of the fermentation were investigated. Moreover, a kinetic model for LA fermentation by Lactobacillus plantarum of ESBPP hydrolysates was developed.

RESULTS

L. plantarum produced a LA concentration 34% higher than that produced by L. casei. The highest LA concentration (30 g L^-1 ) was obtained with L. plantarum when the hydrolysate was supplemented with 5 g L^-1 yeast extract and the pH was controlled with CaCO₃ . The concentration of acetic acid differed depending on the concentration of CaCO₃ added, producing its maximum value with 27 g L^-1 CaCO₃ . The proposed kinetic model was able to predict the evolution of substrates and products depending on the variation of the pH in the hydrolysate, according to the amount of CaCO₃ added.

CONCLUSIONS

ESBPP can be revalorised to produce LA. A pure LA stream or a mixture of LA and acetic acid, depending on the pH control method of the fermentation, can be produced. Thus, this control is of great interest depending on the destination of the effluent. © 2020 Society of Chemical Industry.

Anaerobic digestion of organic waste: Recovery of value-added and inhibitory compounds from liquid fraction of digestate

Anaerobic digestion, as an eco-friendly waste treatment technology, is facing the problem of low stability and low product value. Harvesting value-added products beyond methane and removing the inhibitory compounds will unleash new vitality of anaerobic digestion, which need to be achieved by selective separation of certain compounds. Various methods are reviewed in this study for separating valuable products (volatile fatty acids, medium-chain carboxylic acids, lactic acid) and inhibitory substance (ammonia) from the liquid fraction of digestate, including their performance, applicability, corresponding limitations and roadmaps for improvement. In-situ extraction that allows simultaneous production and extraction is seen as promising approach which carries good potential to overcome the barriers for continuous production. The prospects and challenges of the future development are further analyzed based on in-situ extraction and economics.

Adaptive laboratory evolution principles and applications in industrial biotechnology

Adaptive laboratory evolution (ALE) is an innovative approach for the generation of evolved microbial strains with desired characteristics, by implementing the rules of natural selection as presented in the Darwinian Theory, on the laboratory bench. New as it might be, it has already been used by several researchers for the amelioration of a variety of characteristics of widely used microorganisms in biotechnology. ALE is used as a tool for the deeper understanding of the genetic and/or metabolic pathways of evolution. Another important field targeted by ALE is the manufacturing of products of (high) added value, such as ethanol, butanol and lipids. In the current review, we discuss the basic principles and techniques of ALE, and then we focus on studies where it has been applied to bacteria, fungi and microalgae, aiming to improve their performance to biotechnological procedures and/or inspect the genetic background of evolution. We conclude that ALE is a promising and efficacious method that has already led to the acquisition of useful new microbiological strains in biotechnology and could possibly offer even more interesting results in the future.

Ion-Exchange Technology for Lactic Acid Recovery in Downstream Processing: Equilibrium and Kinetic Parameters

The downstream processing for the separation and purification of lactic acid is a hot research area in the bio-refinery field due to its continuous growing market in different sectors, such as the food, cosmetic and pharmaceutical sectors. In this work, the use of ion-exchange technology for lactic acid recovery is proposed. For that, four anion exchange resins with different polymer structures and functional groups were tested (A100, MN100, A200E and MP64). The sorption process was optimized by the Box–Behnken factorial design, and the experimental data obtained in the sorption process were analyzed by using the response surface methodology and fitted at different isotherms and kinetics models. Moreover, regenerant type, contact time and solid/liquid ratio were evaluated in the desorption process. Results showed that the best resin for lactic acid removal was A100, at pH = 4, with a resin/lactic acid solution ratio of 0.15 g/mL during a maximum of 1 h, achieving 85% of lactic acid removal. Moreover, equilibrium data sorption of lactic acid onto A100 resin was fitted by a Langmuir isotherm and by a kinetic model of a pseudo-second order. In addition, in the desorption process, it was stablished that a resin/regenerant ratio of 0.15 g/mL during 30 min with 0.1 M of NaOH solution provided the best results (4.45 ± 0.08 mg/g).

Fermentation study of Cassava bagasse starch hydrolyzed's using INIAP 650 and INIAP 651 varieties and a strain of Lactobacillus leichmannii for the lactic acid production

Ecuador is an agricultural country, which has an actual production of starch obtained from cassava. Tuber processing residues do not have an economic impact; for example, the cassava bagasse, only used for plant fertilization and animal feeding. This project aimed to study the influence of the fermentation variables (pH and agitation), on the lactic acid production. Enzymatic hydrolysis of cassava bagasse starch for the varieties INIAP 650 and INIAP 651 was performed using α-amylase and glucoamylase. Then, glucose was fermented by Lactobacillus leichmannii ATCC 7830 strains, varying conditions such as agitation (150 rpm and absence) and pH (4.5, 5.0, and 5.5). Finally, the determination of lactic acid was performed by potentiometric and FTIR analysis. Conversions of cassava bagasse to reduced sugars were 71.66 and 85.05 % for INIAP 650 and INIAP 651 varieties. The best lactic acid concentrations were 27.62 and 33.48 g/L, obtained at pH 5.5 and agitation, for INIAP 650 and INIAP 651 varieties. Qualitative analysis conducted by FTIR spectrophotometry confirmed the presence of lactic acid in the reacted products. Lactic acid production from cassava bagasse starch could contribute to the Manabí and Esmeraldas provinces of Ecuador's economic development.

Life cycle and economic assessment of sugarcane bagasse valorization to lactic acid

In this work, detailed life cycle assessment (LCA) and techno-economic analysis (TEA) of a novel lactic acid (LA) production process from sugarcane bagasse is performed, with the objective of identifying process improvement opportunities. Moreover, this is first such study in the Indian context. Experimental data generated at the Vasantdada Sugar Institute (VSI) for upstream processes is combined with ASPEN Plus simulation of the downstream steps for a commercial plant producing 104 tonnes per day of LA. Equipment sizing is performed and costing is done using standard approaches. OpenLCA is used to develop the LCA model and Ecoinvent database is used to quantify life cycle impacts for 1 kg of LA. Different scenarios for the LA plant are studied. Results showed that the pretreatment stage was crucial from both economic and environmental perspectives. The total life cycle climate change impact for production of 1 kg of lactic acid was 4.62 kg CO₂ eq. The product cost of LA was USD 2.9/kg, and a payback time of 6 years was achieved at a selling price of USD 3.21/kg. Scenario analysis has revealed that lactic acid plant annexed to a sugar mill led to significant environmental and economic benefits. Sensitivity analysis has identified opportunities to reduce the life cycle climate change impact to 2.29 kg CO₂ eq. and product cost to USD 1.42/kg through reduced alkali consumption, higher solid loading, and reduced enzyme loading.

Statistical Optimization of Alkali Pretreatment to Improve Sugars Recovery from Spent Coffee Grounds and Utilization in Lactic Acid Fermentation

Biorefinery, which utilizes carbon-neutral biomass as a resource, is attracting attention as a significant alternative in a modern society confronted with climate change. In this study, spent coffee grounds (SCGs) were used as the feedstock for lactic acid fermentation. In order to improve sugar conversion, alkali pretreatment was optimized by a statistical method, namely response surface methodology (RSM). The optimum conditions for the alkali pretreatment of SCGs were determined as follows: 75 °C, 3% potassium hydroxide (KOH) and a time of 2.8 h. The optimum conditions for enzymatic hydrolysis of pretreated SCGs were determined as follows: enzyme complex loading of 30-unit cellulase, 15-unit cellobiase and 50-unit mannanase per g biomass and a reaction time of 96 h. SCG hydrolysates were used as the carbon source for Lactobacillus cultivation, and the conversions of lactic acid by L. brevis ATCC 8287 and L. parabuchneri ATCC 49374 were 40.1% and 55.8%, respectively. Finally, the maximum lactic acid production by L. parabuchneri ATCC 49374 was estimated to be 101.2 g based on 1000 g of SCGs through the optimization of alkali pretreatment and enzymatic hydrolysis.

One-pot production of lactic acid from rice straw pretreated with ionic liquid

Production of platform chemicals has been advocated as a sustainable option to tackle the problems associated with agro-waste management. In this report, for the first time, efforts were made to effectively produce second-generation lactic acid from rice straw pretreated with imidazolium ionic liquid [EMIM][OAc] and subsequently fermented with a promising Lactobacillus plantarum SKL-22 strain saccharified with a commercial cellulase enzyme. Medium optimization was carried out to enhance the lactic acid (LA) yield by response surface methodology. In a 5 L bioreactor, the process was further upscale, and a yield increment of 1.11% was observed. The process using rice straw as substrate led to a LA yield of 36.75 g/L from L. plantarum SKL-22 in a single pot bioprocess. Overall, the above finding has shown the ability of L. plantarum SKL-22 to produce LA from the hydrolysate of rice straw. This study presented a novel environmental-friendly method for LA production.

Biosynthesis of Chlorinated Lactylates in Sphaerospermopsis sp. LEGE 00249

Lactylates are an important group of molecules in the food and cosmetic industries. A series of natural halogenated 1-lactylates, chlorosphaerolactylates (1-4), were recently reported from Sphaerospermopsis sp. LEGE 00249. Here, we identify the cly biosynthetic gene cluster, containing all the necessary functionalities for the biosynthesis of the natural lactylates, based on in silico analyses. Using a combination of stable isotope incorporation experiments and bioinformatic analysis, we propose that dodecanoic acid and pyruvate are the key building blocks in the biosynthesis of 1-4. We additionally report minor analogues of these molecules with varying alkyl chains. This work paves the way to accessing industrially relevant lactylates through pathway engineering.

Efficient Co-Utilization of Biomass-Derived Mixed Sugars for Lactic Acid Production by Bacillus coagulans Azu-10

Lignocellulosic and algal biomass are promising substrates for lactic acid (LA) production. However, lack of xylose utilization and/or sequential utilization of mixed-sugars (carbon catabolite repression, CCR) from biomass hydrolysates by most microorganisms limits achievable titers, yields, and productivities for economical industry-scale production. This study aimed to design lignocellulose-derived substrates for efficient LA production by a thermophilic, xylose-utilizing, and inhibitor-resistant Bacillus coagulans Azu-10. This strain produced 102.2 g/L of LA from 104 g/L xylose at a yield of 1.0 g/g and productivity of 3.18 g/L/h. The CCR effect and LA production were investigated using different mixtures of glucose (G), cellobiose (C), and/or xylose (X). Strain Azu-10 has efficiently co-utilized GX and CX mixture without CCR; however, total substrate concentration (>75 g/L) was the only limiting factor. The strain completely consumed GX and CX mixture and homoferemnatively produced LA up to 76.9 g/L. On the other hand, fermentation with GC mixture exhibited obvious CCR where both glucose concentration (>25 g/L) and total sugar concentration (>50 g/L) were the limiting factors. A maximum LA production of 50.3 g/L was produced from GC mixture with a yield of 0.93 g/g and productivity of 2.09 g/L/h. Batch fermentation of GCX mixture achieved a maximum LA concentration of 62.7 g/L at LA yield of 0.962 g/g and productivity of 1.3 g/L/h. Fermentation of GX and CX mixture was the best biomass for LA production. Fed-batch fermentation with GX mixture achieved LA production of 83.6 g/L at a yield of 0.895 g/g and productivity of 1.39 g/L/h.

Microbial inefficient substrate use through the perspective of resource allocation models

Microorganisms extract energy from substrates following strategies that may seem suboptimal at first glance. Beyond the so-called yield-rate trade-off, resource allocation models, which focus on assigning different functional roles to the limited number of enzymes that a cell can support, offer a framework to interpret the inefficient substrate use by microorganisms. We review here relevant examples of substrate conversions where a significant part of the available energy is not utilised and how resource allocation models offer a mechanistic interpretation thereof, notably for open mixed cultures. Future developments are identified, in particular, the challenge of considering metabolic flexibility towards uncertain environmental changes instead of strict fixed optimality objectives, with the final goal of increasing the prediction capabilities of resource allocation models. Finally, we highlight the relevance of resource allocation to understand and enable a promising biorefinery platform revolving around lactate, which would increase the flexibility of waste-to-chemical biorefinery schemes.

Open simultaneous saccharification and fermentation of l-lactic acid by complete utilization of sweet sorghum stalk: a water-saving process

A complete and efficient utilization of sweet sorghum stalk including sweet sorghum juice (SSJ) and sweet sorghum bagasse (SSB) was achieved via the open simultaneous saccharification and fermentation (SSF) of l-lactic acid. To simplify the pretreatment process and reduce water consumption, a combined hydrolysis approach was applied and the NaOH-pretreated liquor (SL) was utilized as a partial neutralizing agent. In order to further enhance the product titer, the acid hydrolysate of SSJ (SSJAH) was fed, and MgO was used as a neutralizing agent. A product titer of 94 g L-1 was obtained with a productivity of 1.55 g L-1 h-1, and the yield reached 98.31%. Totally, 274.79 g l-lactic acid was produced from 1 kg sweet sorghum stalk, and 83.22% water was saved compared with the previous study based on alkali pretreatment of SSB. This study provides an effective process for l-lactic acid biosynthesis from lignocellulosic substrates.

Substrate availability drives mixed culture fermentation of glucose to lactate at steady state

Mixed-culture fermentation (MCF) enables carbon recycling from complex organic waste streams into valuable feedstock chemicals. Using complex microbial consortia, MCF systems can be tuned to produce a range of biochemicals to meet market demand. However, the metabolic mechanisms and community interactions which drive biochemical production changes under differing conditions are currently poorly understood. These mechanisms are critical to useful MCF production models. Furthermore, predictable product transitions are currently limited to pH-driven changes between butyrate and ethanol, and chain-elongation (fed by lactate, acetate, and ethanol) to butyrate, valerate, and hexanoate. Lactate, a high-value biopolymer feedstock chemical, has been observed in transition states, but sustained production has not been described. In this study, steady state lactate production was achieved by increasing the organic loading rate of a butyrate-producing system from limiting to nonlimiting conditions at pH 5.5. Crucially, butyrate production resumed upon return to substrate-limited conditions. 16S ribosomal DNA community profiling combined with metaproteomics demonstrated that the butyrate-producing lineage Megasphaera redirected carbon flow through the methylglyoxal bypass when substrate was nonlimiting, which altered the community structure and metabolic expression toward lactate production. This metabolic mechanism can be included in future MCF models to describe the changes in product generation in substrate nonlimiting conditions.

A simple downstream processing protocol for the recovery of lactic acid from the fermentation broth

Lactic acid is one of the essential platform chemicals, and despite the availability of a range of downstream processes, its effective recovery is still elusive. A phase partitioning process using n-butanol and a chaotropic salt ammonium sulphate was developed to recover lactic acid from the fermentation broth of Lactobacillus pentosus SKL-18. During the optimization of various process parameters, the extraction medium's pH was found to be critical, with 2.5 being the best. The optimized process resulted in a lactic acid yield of 86% and found it to be 93% pure. The purity and characteristics of lactic acid were confirmed by FTIR and NMR spectra. This solvent-based extraction procedure is an economical and straightforward downstream process for purifying lactic acid produced from agro- and bakery-residues. The pure lactic acid can further be used for enzymatic synthesis of high value-added product PLA, a biodegradable and biocompatible plastics.

Transcriptome profile of carbon catabolite repression in an efficient l-(+)-lactic acid-producing bacterium Enterococcus mundtii QU25 grown in media with combinations of cellobiose, xylose, and glucose

Enterococcus mundtii QU25, a non-dairy lactic acid bacterium of the phylum Firmicutes, is capable of simultaneously fermenting cellobiose and xylose, and is described as a promising strain for the industrial production of optically pure l-lactic acid (≥ 99.9%) via homo-fermentation of lignocellulosic hydrolysates. Generally, Firmicutes bacteria show preferential consumption of sugar (usually glucose), termed carbon catabolite repression (CCR), while hampering the catabolism of other sugars. In our previous study, QU25 exhibited apparent CCR in a glucose-xylose mixture phenotypically, and transcriptional repression of the xylose operon encoding initial xylose metabolism genes, likely occurred in a CcpA-dependent manner. QU25 did not exhibit CCR phenotypically in a cellobiose-xylose mixture. The aim of the current study is to elucidate the transcriptional change associated with the simultaneous utilization of cellobiose and xylose. To this end, we performed RNA-seq analysis in the exponential growth phase of E. mundtii QU25 cells grown in glucose, cellobiose, and/or xylose as either sole or co-carbon sources. Our transcriptomic data showed that the xylose operon was weakly repressed in cells grown in a cellobiose-xylose mixture compared with that in cells grown in a glucose-xylose mixture. Furthermore, the gene expression of talC, the sole gene encoding transaldolase, is expected to be repressed by CcpA-mediated CCR. QU25 metabolized xylose without using transaldolase, which is necessary for homolactic fermentation from pentoses using the pentose-phosphate pathway. Hence, the metabolism of xylose in the presence of cellobiose by QU25 may have been due to 1) sufficient amounts of proteins encoded by the xylose operon genes for xylose metabolism despite of the slight repression of the operon, and 2) bypassing of the pentose-phosphate pathway without the TalC activity. Accordingly, we have determined the targets of genetic modification in QU25 to metabolize cellobiose, xylose and glucose simultaneously for application of the lactic fermentation from lignocellulosic hydrolysates.

Combining the production of L-lactic acid with the production of feed protein concentrates from alfalfa

The production of L-lactic acid was investigated in combination with the production of protein concentrates in the frame of a green biorefinery for efficient utilization of grasses and legume crops. Alfalfa green juice was the sole substrate utilized for initial lactic acid fermentation with Lactobacillus salivarius, Lactobacillus paracasei or Bacillus coagulans in order to drop the pH and precipitate the plant proteins present in the juice. Afterwards, proteins were separated by microfiltration with 40-42% of protein recovery into protein concentrates, suited for feeding monogastric animals. The (residual) brown juice was investigated as source of nutrients for producing L-lactic acid from glucose or xylose with B. coagulans A107 or B. coagulans A166, respectively. Fermentation of glucose (30, 60, 100 g L^-1) resulted in productivities of 2.8-4.0 g L^-1 h^-1 and yields of 0.85-0.91 g LA per g consumed glucose. Fermentation of xylose (30, 60 g L^-1) resulted productivities of 1.1-2.3 g L^-1 h^-1 and yields of 0.83-0.88 g LA per g consumed xylose. Comparing different brown juices, initial green juice fermentation with B. coagulans is recommended if the brown juice is to be used for producing L-lactic acid. Based on our results, it is possible to combine protein recovery with lactic acid production, and the brown juice proved to be a good nutrient source for L-lactic acid production with high optical purities.

Resource allocation explains lactic acid production in mixed-culture anaerobic fermentations

Lactate production in anaerobic carbohydrate fermentations with mixed cultures of microorganisms is generally observed only in very specific conditions: the reactor should be run discontinuously and peptides and B vitamins must be present in the culture medium as lactic acid bacteria (LAB) are typically auxotrophic for amino acids. State-of-the-art anaerobic fermentation models assume that microorganisms optimise the adenosine triphosphate (ATP) yield on substrate and therefore they do not predict the less ATP efficient lactate production, which limits their application for designing lactate production in mixed-culture fermentations. In this study, a metabolic model taking into account cellular resource allocation and limitation is proposed to predict and analyse under which conditions lactate production from glucose can be beneficial for microorganisms. The model uses a flux balances analysis approach incorporating additional constraints from the resource allocation theory and simulates glucose fermentation in a continuous reactor. This approach predicts lactate production is predicted at high dilution rates, provided that amino acids are in the culture medium. In minimal medium and lower dilution rates, mostly butyrate and no lactate is predicted. Auxotrophy for amino acids of LAB is identified to provide a competitive advantage in rich media because less resources need to be allocated for anabolic machinery and higher specific growth rates can be achieved. The Matlab™ codes required for performing the simulations presented in this study are available at https://doi.org/10.5281/zenodo.4031144.

Graphene Derivatives in Biopolymer-Based Composites for Food Packaging Applications

This review aims to showcase the current use of graphene derivatives, graphene-based nanomaterials in particular, in biopolymer-based composites for food packaging applications. A brief introduction regarding the valuable attributes of available and emergent bioplastic materials is made so that their contributions to the packaging field can be understood. Furthermore, their drawbacks are also disclosed to highlight the benefits that graphene derivatives can bring to bio-based formulations, from physicochemical to mechanical, barrier, and functional properties as antioxidant activity or electrical conductivity. The reported improvements in biopolymer-based composites carried out by graphene derivatives in the last three years are discussed, pointing to their potential for innovative food packaging applications such as electrically conductive food packaging.

Construction of lactic acid overproducing Clostridium thermocellum through enhancement of lactate dehydrogenase expression

Rapid expansion of global market of lactic acid (LA) has prompted research towards cheaper and more eco-friendly strategies for its production. Nowadays, LA is produced mainly through fermentation of simple sugars or starchy biomass (e.g. corn) and its price is relatively high. Lignocellulose could be an advantageous alternative feedstock for LA production owing to its high abundance and low cost. However, the most effective natural producers of LA cannot directly ferment lignocellulose. So far, metabolic engineering aimed at developing microorganisms combining efficient LA production and cellulose hydrolysis has been generally based on introducing designer cellulase systems in natural LA producers. In the present study, the approach consisted in improving LA production in the natural cellulolytic bacterium Clostridium thermocellum DSM1313. The expression of the native lactate dehydrogenase was enhanced by functional replacement of its original promoter with stronger ones resulting in a 10-fold increase in specific activity, which resulted in a 2-fold increase of LA yield. It is known that eliminating allosteric regulation can also increase lactic acid production in C. thermocellum, however we were unable to insert strong promoters upstream of the de-regulated ldh gene. A strategy combining these regulations and inactivation of parasitic pathways appears essential for developing a homolactic C. thermocellum.

Lactic acid production - producing microorganisms and substrates sources-state of art

Lactic acid is an organic compound produced via fermentation by different microorganisms that are able to use different carbohydrate sources. Lactic acid bacteria are the main bacteria used to produce lactic acid and among these, Lactobacillus spp. have been showing interesting fermentation capacities. The use of Bacillus spp. revealed good possibilities to reduce the fermentative costs. Interestingly, lactic acid high productivity was achieved by Corynebacterium glutamicum and E. coli, mainly after engineering genetic modification. Fungi, like Rhizopus spp. can metabolize different renewable carbon resources, with advantageously amylolytic properties to produce lactic acid. Additionally, yeasts can tolerate environmental restrictions (for example acidic conditions), being the wild-type low lactic acid producers that have been improved by genetic manipulation. Microalgae and cyanobacteria, as photosynthetic microorganisms can be an alternative lactic acid producer without carbohydrate feed costs. For lactic acid production, it is necessary to have substrates in the fermentation medium. Different carbohydrate sources can be used, from plant waste as molasses, starchy, lignocellulosic materials as agricultural and forestry residues. Dairy waste also can be used by the addition of supplementary components with a nitrogen source.

Encapsulation of two fermentation agents, Lactobacillus sakei and calcium ions in microspheres

Alginate microspheres loaded with two fermentation active agents, calcium cations and strain LS0296 identified as Lactobacillus sakei, have been prepared and characterized. The role of calcium cation is twofold, it acts as gelling cation and as fermentation active agent. Encapsulation and the presence of calcium ions in the same compartment do not inhibit the activity of LS0296. Molecular interactions in microspheres are complex, including mainly hydrogen bonds and electrostatic interactions. In vitro calcium cations and strain LS0296 release profiles were fitted to the Korsmeyer-Peppas empirical model. The calcium cation release process is driven at first by Fickian diffusion through microspheres and then by anomalous transport kinetics. The in vitro LS0296 release process is driven by Fickian diffusion through microspheres showing a much slower releasing rate than calcium cations. The release of LS0296 strain is followed by a decrease in the pH value. Results obtained give us a new insight into complex interactions between bacterial cultures and microsphere constituents. Prepared formulations of calcium alginate microspheres loaded with LS0296 could be used as a new promising tool and a model for different starter cultures encapsulation and use in the production of fermented foods.

Hydrolyzed Agricultural Residues—Low-Cost Nutrient Sources for l-Lactic Acid Production

Lactic acid is a building block for polylactic acid, which is one of the most promising polymers based on renewable resources and is used mainly in packaging industry. This bio-based polymer is biodegradable and provides an ecological and economical alternative to petrochemical plastics. The largest cost blocks of biotechnological lactic acid production, accounting for up to 38% of the total costs, are substrate and nutrient sources, such as peptone, meat, and yeast extract. Based on a systematic analysis of nutritional requirements, the substitution of yeast extract by low-cost protein-rich agricultural hydrolysates was estimated for the production of l-lactic acid with Lactobacillus casei. Cultivations in 24-well microtiter plates enabled analysis of nutrient requirements and the usage of various hydrolysates with a high parallel throughput and repeated sampling. Rapeseed meal (RM) and distillers’ dried grains with solubles (DDGS) were tested as low-cost protein-rich agricultural residues. By using chemically or enzymatically hydrolyzed rapeseed meal or DDGS, 70% of the nutrient sources was replaced in the fermentation process at identical productivity and product yields. All in all, the total costs of l-lactic acid production with Lactobacillus casei could potentially be reduced by up to 23%.

Applying Non-canonical Redox Cofactors in Fermentation Processes

Fermentation processes are used to sustainably produce chemicals and as such contribute to the transition to a circular economy. The maximum theoretical yield of a conversion can only be approached if all electrons present in the substrate end up in the product. Control over the electrons is therefore crucial. However, electron transfer via redox cofactors results in a diffuse distribution of electrons over metabolism. To overcome this challenge, we propose to apply non-canonical redox cofactors (NRCs) in metabolic networks: cofactors that channel electrons exclusively from substrate to product, forming orthogonal circuits for electron transfer.

An oxidoreductase gene ZMO1116 enhances the p-benzoquinone biodegradation and chiral lactic acid fermentability of Pediococcus acidilactici

p-Benzoquinone (BQ) is a lignin-derived inhibitor to microbial strains. Unlike the furan inhibitors, p-benzoquinone is recalcitrant to traditional detoxification methods. This study shows a biological degradation of p-benzoquinone and a simultaneous D-lactic acid fermentation by an engineered Pediococcus acidilactici strain. The overexpression of an oxidoreductase gene ZMO1116 from Zymomonas mobilis encoding oxidoreductase was identified to improve the D-lactic acid fermentability of P. acidilactici against p-benzoquinone. The gene ZMO1116 was integrated into the genome of P. acidilactici and enabled the engineered P. acidilactici to convert p-benzoquinone into less toxic hydroquinone (HQ), resulting in the improved p-benzoquinone tolerance. Simultaneous saccharification and co-fermentation (SSCF) was conducted using the pretreated and biodetoxified corn stover containing p-benzoquinone, the D-lactic acid production of the engineered strain (123.8 g/L) was 21.4 % higher than the parental strain (102.0 g/L). This study provides a practical method on robust p-benzoquinone tolerance and efficient cellulosic chiral lactic acid fermentation from lignocellulose feedstock.

Batch and Continuous Lactic Acid Fermentation Based on A Multi-Substrate Approach

The utilisation of waste materials and industrial residues became a priority within the bioeconomy concept and the production of biobased chemicals. The aim of this study was to evaluate the feasibility to continuously produce L-lactic acid from different renewable substrates, in a multi-substrate strategy mode. Based on batch experiments observations, Bacillus coagulans A534 strain was able to continuously metabolise acid whey, sugar beet molasses, sugar bread, alfalfa press green juice and tapioca starch. Additionally, reference experiments showed its behaviour in standard medium. Continuous fermentations indicated that the highest productivity was achieved when molasses was employed with a value of 10.34 g·L⁻¹·h⁻¹, while the lactic acid to sugar conversion yield was 0.86 g·g⁻¹. This study demonstrated that LA can be efficiently produced in continuous mode regardless the substrate, which is a huge advantage in comparison to other platform chemicals.

Metabolically engineered Lactobacillus gasseri JCM 1131 as a novel producer of optically pure L- and D-lactate

High-quality environmentally-friendly bioplastics can be produced by mixing poly-L-lactate with poly-D-lactate. On an industrial scale, this process simultaneously consumes large amounts of both optically pure lactate stereoisomers. However, because optimal growth conditions of L-lactate producers often differ from those of D-lactate producers, each stereoisomer is produced in a specialised facility, which raises cost and lowers sustainability. To address this challenge, we metabolically engineered Lactobacillus gasseri JCM 1131^T, a bioprocess-friendly and genetically malleable strain of homofermentative lactic acid bacterium, to efficiently produce either pure L- or pure D-lactate under the same bioprocess conditions. Transformation of L. gasseri with plasmids carrying additional genes for L- or D-lactate dehydrogenases failed to affect the ratio of produced stereoisomers, but inactivation of the endogenous genes created strains which yielded 0.96 g of either L- or D-lactate per gram of glucose. In this study, the plasmid pHBintE, routinely used for gene disruption in Bacillus megaterium, was used for the first time to inactivate genes in lactobacilli. Strains with inactivated genes for endogenous lactate dehydrogenases efficiently fermented sugars released by enzymatic hydrolysis of alkali pre-treated wheat straw, an abundant lignocellulose-containing raw material, producing 0.37-0.42 g of lactate per gram of solid part of alkali-treated wheat straw. Thus, the constructed strains are primed to serve as producers of both optically pure L-lactate and D-lactate in the next-generation biorefineries.

Sustainable production of bio-based chemicals and polymers via integrated biomass refining and bioprocessing in a circular bioeconomy context

The sustainable production of bio-based chemicals and polymers is highly dependent on the development of viable biorefinery concepts using crude renewable resources for the production of diversified products. Within this concept, this critical review presents the availability of fractionated co-products and fermentable sugars that could be derived from major industrial and food supply chain side streams in EU countries. Fermentable sugars could be used for the production of bio-based chemicals and polymers. The implementation of biorefinery concepts in industry should depend on the evaluation of process efficiency and sustainability including techno-economic, environmental and social impact assessment following circular bioeconomy principles. Relevant sustainability indicators and End-of-Life scenarios have been presented. A case study on the techno-economic evaluation of bio-based succinic acid production from the organic fraction of municipal solid waste has been presented focusing on the evaluation of process profitability and feedstock requirements.

Production of Lactic Acid from Carob, Banana and Sugarcane Lignocellulose Biomass

Lignocellulosic biomass from agricultural residues is a promising feedstock for lactic acid (LA) production. The aim of the current study was to investigate the production of LA from different lignocellulosic biomass. The LA production from banana peduncles using strain Bacillus coagulans with yeast extract resulted in 26.6 g LA·L⁻¹, and yield of 0.90 g LA·g⁻¹ sugars. The sugarcane fermentation with yeast extract resulted in 46.5 g LA·L⁻¹, and yield of 0.88 g LA·g⁻¹ sugars. Carob showed that addition of yeast extract resulted in higher productivity of 3.2 g LA·L⁻¹·h⁻¹ compared to without yeast extract where1.95 g LA·L⁻¹·h⁻¹ was obtained. Interestingly, similar LA production was obtained by the end where 54.8 and 51.4 g·L⁻¹ were obtained with and without yeast extract, respectively. A pilot scale of 35 L using carob biomass fermentation without yeast extract resulted in yield of 0.84 g LA·g⁻¹ sugars, and productivity of 2.30 g LA·L⁻¹·h⁻¹ which indicate a very promising process for future industrial production of LA.

Evaluation of Product Distribution in Chemostat and Batch Fermentation in Lactic Acid-Producing Komagataella phaffii Strains Utilizing Glycerol as Substrate

Lactic acid is the monomeric unit of polylactide (PLA), a bioplastic widely used in the packaging, automotive, food, and pharmaceutical industries. Previously, the yeast Komagataella phaffii was genetically modified for the production of lactate from glycerol. For this, the bovine L-lactate dehydrogenase- (LDH)-encoding gene was inserted and the gene encoding the pyruvate decarboxylase (PDC) was disrupted, resulting in the GLp strain. This showed a yield of 67% L-lactic acid and 20% arabitol as a by-product in batches with oxygen limitation. Following up on these results, the present work endeavored to perform a detailed study of the metabolism of this yeast, as well as perturbing arabitol synthesis in an attempt to increase lactic acid titers. The GLp strain was cultivated in a glycerol-limited chemostat at different dilution rates, confirming that the production of both lactic acid and arabitol is dependent on the specific growth rate (and consequently on the concentration of the limiting carbon source) as well as on the oxygen level. Moreover, disruption of the gene encoding arabitol dehydrogenase (ArDH) was carried out, resulting in an increase of 20% in lactic acid and a 50% reduction in arabitol. This study clarifies the underlying metabolic reasons for arabitol formation in K. phaffii and points to ways for improving production of lactic acid using K. phaffii as a biocatalyst.