Bacterial polyhydroxyalkanoates: Still fabulous?

Sustainable Materials with Enhanced Mechanical Properties Based on Industrial Polyhydroxyalkanoates Reinforced with Organomodified Sepiolite and Montmorillonite

Microplastics have become one of the greatest environmental challenges worldwide. To turn this dramatic damage around, EU regulators now want to ensure that plastic itself is fully recyclable or biodegradable. The aim of the present work is to develop a biobased and biodegradable biocomposite based on commercial polyhydroxyalkanoates (PHAs) and nanoclays, with the objective of achieving a reduction of rancid odour while avoiding any loss in thermomechanical properties, thus tackling two key disadvantages of PHAs. This research aims at completely characterising the structural, thermal and mechanical behaviour of the formulations developed, understanding the compatibility mechanisms in order to be able to assess the best commercial combinations for industrial applications in the packaging and automotive sectors. We report the development of nine nanobiocomposite materials based on three types of commercial PHA matrices: a linear poly(3-hydroxybutyrate) (P3HB); two copolymers based on poly(3-hydroxybutyrate)-co-poly(4-hydroxybutyrate) (P3HB-co-P4HB); and nanoclays, which represent a different polar behaviour. Dispersion achieved is highly relevant compared with literature results. Our findings show impressive mechanical enhancements, in particular for P3HB reinforced with sepiolite modified via aminosilanes.

Complete genome sequence of the halophilic PHA-producing bacterium Halomonas sp. SF2003: insights into its biotechnological potential

A halophilic Gram-negative eubacterium was isolated from the Iroise Sea and identified as an efficient producer of polyhydroxyalkanoates (PHA). The strain, designated SF2003, was found to belong to the Halomonas genus on the basis of 16S rRNA gene sequence similarity. Previous biochemical tests indicated that the Halomonas sp. strain SF2003 is capable of supporting various culture conditions which sometimes can be constraining for marine strains. This versatility could be of great interest for biotechnological applications. Therefore, a complete bacterial genome sequencing and de novo assembly were performed using a PacBio RSII sequencer and Hierarchical Genome Assembly Process software in order to predict Halomonas sp. SF2003 metabolisms, and to identify genes involved in PHA production and stress tolerance. This study demonstrates the complete genome sequence of Halomonas sp. SF2003 which contains a circular 4,36 Mbp chromosome, and replaces the strain in a phylogenetic tree. Genes related to PHA metabolism, carbohydrate metabolism, fatty acid metabolism and stress tolerance were identified and a comparison was made with metabolisms of relative species. Genes annotation highlighted the presence of typical genes involved in PHA biosynthesis such as phaA, phaB and phaC and enabled a preliminary analysis of their organization and characteristics. Several genes of carbohydrates and fatty acid metabolisms were also identified which provided helpful insights into both a better knowledge of the intricacies of PHA biosynthetic pathways and of production purposes. Results show the strong versatility of Halomonas sp. SF2003 to adapt to various temperatures and salinity which can subsequently be exploited for industrial applications such as PHA production.

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.

Bioreactor Operating Strategies for Improved Polyhydroxyalkanoate (PHA) Productivity

Microbial polyhydroxyalkanoates (PHAs) are promising biodegradable polymers that may alleviate some of the environmental burden of petroleum-derived polymers. The requirements for carbon substrates and energy for bioreactor operations are major factors contributing to the high production costs and environmental impact of PHAs. Improving the process productivity is an important aspect of cost reduction, which has been attempted using a variety of fed-batch, continuous, and semi-continuous bioreactor systems, with variable results. The purpose of this review is to summarize the bioreactor operations targeting high PHA productivity using pure cultures. The highest volumetric PHA productivity was reported more than 20 years ago for poly(3-hydroxybutryate) (PHB) production from sucrose (5.1 g L⁻¹ h⁻¹). In the time since, similar results have not been achieved on a scale of more than 100 L. More recently, a number fed-batch and semi-continuous (cyclic) bioreactor operation strategies have reported reasonably high productivities (1 g L⁻¹ h⁻¹ to 2 g L⁻¹ h⁻¹) under more realistic conditions for pilot or industrial-scale production, including the utilization of lower-cost waste carbon substrates and atmospheric air as the aeration medium, as well as cultivation under non-sterile conditions. Little development has occurred in the area of fully continuously fed bioreactor systems over the last eight years.

Polyhydroxyalkanoate synthesis based on glycerol and implementation of the process under conditions of pilot production

The present study addresses the synthesis and properties of polyhydroxyalkanoates (PHA) of different composition synthesized by Cupriavidus eutrophus B-10646 using glycerol as a carbon substrate. Poly(3-hydroxybutyrate) [P(3HB)] was effectively synthesized in fed-batch culture in a 30-L fermenter on glycerol of various purification degrees, with 99.5, 99.7, and 82.1% content of the main component. Purified glycerol (99.7%) was used for 150-L pilot scale fermentation. The total biomass and P(3HB) concentration reached 110 and 85.8 g/L, respectively, after 45 h of fed-batch fermentation. An average volumetric productivity of P(3HB) was 1.83 g/(L h). The degree of crystallinity and molecular weight of P(3HB) synthesized on glycerol were lower than and temperature characteristics were the same as those of P(3HB) synthesized on sugars.

Optimization of Extrusion Variables and Maleic Anhydride Content on Biopolymer Blends Based on Poly(hydroxybutyrate-co-hydroxyvalerate)/Poly(vinyl acetate) with Tapioca Starch

Poly(3-hyroxybutyrate-co-3-hydroxyvalerate) (PHBV), poly(vinyl acetate) (PVAc), and tapioca starch are environment-friendly materials. The present study used these materials to produce biodegradable plastic pellets by melt extrusion. The tapioca starch content of composite formulations, the maleic anhydride content, and the screw speed of the extruder were chosen as variables for the extrusion process. A Box-Behnken response surface design was used to establish mathematical models to predict the relationship between the operating variables and the objective attributes (tensile strength, elongation at break, and water absorption) of the blends. Blend morphology was also assessed. The regression coefficients revealed that the extrusion parameters most significantly affecting extrudate responses were tapioca starch content and maleic anhydride content, both showing significant (p < 0.01) linear effects. The results of the analysis of variance found the models are in good agreement with experimental results as informed by high correlation coefficients (R² > 0.9), with no significant lack of fit. From the numerical analysis, optimized operating variables (20.13% tapioca starch content, 10.14% maleic anhydride content, and a screw speed of 41.3 rpm) produced a product with optimum values of 16.4 MPa tensile strength, 13.2% elongation at break, and 30.94% water absorption.

Carbon flux to growth or polyhydroxyalkanoate synthesis under microaerophilic conditions is affected by fatty acid chain-length in Pseudomonas putida LS46

Economical production of medium-chain length polyhydroxyalkanoates (mcl-PHA) is dependent on efficient cultivation processes. This work describes growth and mcl-PHA synthesis characteristics of Pseudomonas putida LS46 when grown on medium-chain length fatty acids (octanoic acid) and lower-cost long-chain fatty acids (LCFAs, derived from hydrolyzed canola oil) in microaerophilic environments. Growth on octanoic acid ceased when the oxygen uptake rate was limited by the oxygen transfer rate, and mcl-PHA accumulated to 61.9% of the cell dry mass. From LCFAs, production of non-PHA cell mass continued at a rate of 0.36 g L^-1 h^-1 under oxygen-limited conditions, while mcl-PHA accumulated simultaneously to 31% of the cell dry mass. The titer of non-PHA cell mass from LCFAs at 14 h post-inoculation was double that obtained from octanoic acid in bioreactors operated with identical feeding and aeration conditions. While the productivity for octanoic acid was higher by 14 h, prolonged cultivation on LCFAs achieved similar productivity but with twice the PHA titer. Simultaneous co-feeding of each substrate demonstrated the continued cell growth under microaerophilic conditions characteristic of LCFAs, and the resulting polymer was dominant in C8 monomers. Furthermore, co-feeding resulted in improved PHA titer and volumetric productivity compared to either substrate individually. These results suggest that LCFAs improve growth of P. putida in oxygen-limited environments and could reduce production costs since more non-PHA cell mass, the cellular factories required to produce mcl-PHA and the most oxygen-intensive cellular process, can be produced for a given oxygen transfer rate.

A non-naturally-occurring P(3HB-co-3HAMCL) is produced by recombinant Pseudomonas sp. from an unrelated carbon source

Pseudomonas sp. PHA^- was used as host for PHA biosynthesis genes from Aeromonas sp. to produce 3HB-co-3HA_MCL from glucose with no supply of co-substrates. A non-naturally-occurring PHA composed mainly of 3HB, 3HHx and 3HD (3HO, 3HDdΔ₅ and 3HDd monomers were detected in smaller amounts) was obtained. The polymer was extracted using two different solvents (acetone and chloroform) and subject to the following characterization tests: FTIR, DSC, TGA and GPC. The latter suggests a block copolymer since a single and narrow elution peak was observed for each sample. The DSC results ruled out the possibility of a random copolymer and agrees with a single copolymer composed of two blocks: one with the typical composition of PHA_MCL produced by Pseudomonas and another containing 3HB and 3HHx with a high 3HHx molar fraction. Thus, this study increases the perspectives of P(3HB-co-3HA_MCL) production from carbohydrates as the sole carbon source.

Challenges of scaling-up PHA production from waste streams. A review

The search for new materials that replace fossil fuel-based plastics has been focused on biopolymers with similar physicochemical properties to fossil fuel-based plastics, such as Polyhydroxyalkanoates (PHA). The present paper reviews the challenges of scaling-up PHA production from waste streams during the period from 2014 to 2016, focusing on the feasibility of the alternatives and the most promising alternatives to its scaling-up. The reviewed research studies mainly focus on reducing costs or obtaining more valuable polymers. In the future, the integration of PHA production into processes such as wastewater treatment plants, hydrogen production or biodiesel factories could enhance its implementation at industrial scale.

Production and Characterization of Polyhydroxyalkanoate from Lignin Derivatives by Pandoraea sp. ISTKB

The present study investigates polyhydroxyalkanoate (PHA) production from lignin and its derivatives by a previously reported lignin-degrading bacterial strain Pandoraea sp. ISTKB. PHA production was screened by fluorescence microscopy and flow cytometry using a Nile red stain. PHA and biomass accumulation, while screening, was found to be maximum on 4-hydroxybenzoic acid followed by p-coumaric acid, vanillic acid, 2,6-dimethoxyphenol, and kraft lignin after 96 h. Monomer composition was analyzed by gas chromatography-mass spectrometry (GC-MS) and was followed by Fourier transform infrared and ¹H NMR analysis, indicating PHA to be a copolymer of P(hydroxybutyrate-co-hydroxyvalerate). Genomic analysis of Pandoraea sp. ISTKB also complemented the results of GC-MS and NMR, and the relevant genes responsible for the synthesis of small chain length PHA were discovered in the genome. Process parameters were optimized by response surface methodology for enhanced production of PHA and biomass on 4-hydroxybenzoate. Optimization results showed 30 and 66% increase in the biomass and PHA production, respectively. The results obtained were promising and indicated that if lignin is depolymerized into low-molecular-weight intermediates, then it can easily be utilized and converted into value-added products like PHA by microbes.

Microbial conversion of biomass into bio-based polymers

The worldwide market for plastics is rapidly growing, and plastics polymers are typically produced from petroleum-based chemicals. The overdependence on petroleum-based chemicals for polymer production raises economic and environmental sustainability concerns. Recent progress in metabolic engineering has expanded fermentation products from existing aliphatic acids or alcohols to include aromatic compounds. This diversity provides an opportunity to expand the development and industrial uses of high-performance bio-based polymers. However, most of the biomonomers are produced from edible sugars or starches that compete directly with food and feed uses. The present review focuses on recent progress in the microbial conversion of biomass into bio-based polymers, in which fermentative products from renewable feedstocks serve as biomonomers for the synthesis of bio-based polymers. In particular, the production of biomonomers from inedible lignocellulosic feedstocks by metabolically engineered microorganisms and the synthesis of bio-based engineered plastics from the biological resources are discussed.

Advances in Polyhydroxyalkanoate (PHA) Production

This editorial paper provides a synopsis of the contributions to the Bioengineering special issue “Advances in Polyhydroxyalkanoate (PHA) Production”. It illustrates the embedding of the issue’s individual research articles in the current global research and development landscape related to polyhydroxyalkanoates (PHA). The article shows how these articles are interrelated to each other, reflecting the entire PHA process chain including strain selection, metabolic and genetic considerations, feedstock evaluation, fermentation regimes, process engineering, and polymer processing towards high-value marketable products.

Food waste conversion to microbial polyhydroxyalkanoates

Polyhydroxyalkanoates (PHAs) are biopolymers with desirable material properties similar to petrochemically derived plastics. PHAs are naturally produced by a wide range of microorganisms as a carbon storage mechanism and can accumulate to significantly high levels. PHAs are an environmentally friendly alternative to their petroleum counterparts because they can be easily degraded, potentially reducing the burden on municipal waste systems. Nevertheless, widespread use of PHAs is not currently realistic due to a variety of factors. One of the major constraints of large-scale PHA production is the cost of carbon substrate for PHA-producing microbes. The cost of production could potentially be reduced with the use of waste carbon from food-related processes. Food wastage is a global issue and therefore harbours immense potential to create valuable bioproducts. This article's main focus is to examine the state of the art of converting food-derived waste into carbon substrates for microbial metabolism and subsequent conversion into PHAs.

Recent Advances and Challenges towards Sustainable Polyhydroxyalkanoate (PHA) Production

Sustainable biofuels, biomaterials, and fine chemicals production is a critical matter that research teams around the globe are focusing on nowadays. Polyhydroxyalkanoates represent one of the biomaterials of the future due to their physicochemical properties, biodegradability, and biocompatibility. Designing efficient and economic bioprocesses, combined with the respective social and environmental benefits, has brought together scientists from different backgrounds highlighting the multidisciplinary character of such a venture. In the current review, challenges and opportunities regarding polyhydroxyalkanoate production are presented and discussed, covering key steps of their overall production process by applying pure and mixed culture biotechnology, from raw bioprocess development to downstream processing.

Model-based intensification of a fed-batch microbial process for the maximization of polyhydroxybutyrate (PHB) production rate

An integrated metabolic-polymerization-macroscopic model, describing the microbial production of polyhydroxybutyrate (PHB) in Azohydromonas lata bacteria, was developed and validated using a comprehensive series of experimental measurements. The model accounted for biomass growth, biopolymer accumulation, carbon and nitrogen sources utilization, oxygen mass transfer and uptake rates and average molecular weights of the accumulated PHB, produced under batch and fed-batch cultivation conditions. Model predictions were in excellent agreement with experimental measurements. The validated model was subsequently utilized to calculate optimal operating conditions and feeding policies for maximizing PHB productivity for desired PHB molecular properties. More specifically, two optimal fed-batch strategies were calculated and experimentally tested: (1) a nitrogen-limited fed-batch policy and (2) a nitrogen sufficient one. The calculated optimal operating policies resulted in a maximum PHB content (94% g/g) in the cultivated bacteria and a biopolymer productivity of 4.2 g/(l h), respectively. Moreover, it was demonstrated that different PHB grades with weight average molecular weights of up to 1513 kg/mol could be produced via the optimal selection of bioprocess operating conditions.

Environmental performance of bio-based and biodegradable plastics: the road ahead

This review provides a critical discussion as to the future direction of plastic materials, including balancing factors such as biodegradability and longevity, effects of additive compounds, feedstock developments, and environmental considerations.