Production of microbial polyesters: fermentation and downstream processes

Sustainable Valorization of Bioplastic Waste: A Review on Effective Recycling Routes for the Most Widely Used Biopolymers

Plastics-based materials have a high carbon footprint, and their disposal is a considerable problem for the environment. Biodegradable bioplastics represent an alternative on which most countries have focused their attention to replace of conventional plastics in various sectors, among which food packaging is the most significant one. The evaluation of the optimal end-of-life process for bioplastic waste is of great importance for their sustainable use. In this review, the advantages and limits of different waste management routes-biodegradation, mechanical recycling and thermal degradation processes-are presented for the most common categories of biopolymers on the market, including starch-based bioplastics, PLA and PBAT. The analysis outlines that starch-based bioplastics, unless blended with other biopolymers, exhibit good biodegradation rates and are suitable for disposal by composting, while PLA and PBAT are incompatible with this process and require alternative strategies. The thermal degradation process is very promising for chemical recycling, enabling building blocks and the recovery of valuable chemicals from bioplastic waste, according to the principles of a sustainable and circular economy. Nevertheless, only a few articles have focused on this recycling process, highlighting the need for research to fully exploit the potentiality of this waste management route.

Emergent Approaches to Efficient and Sustainable Polyhydroxyalkanoate Production

Petroleum-derived plastics dominate currently used plastic materials. These plastics are derived from finite fossil carbon sources and were not designed for recycling or biodegradation. With the ever-increasing quantities of plastic wastes entering landfills and polluting our environment, there is an urgent need for fundamental change. One component to that change is developing cost-effective plastics derived from readily renewable resources that offer chemical or biological recycling and can be designed to have properties that not only allow the replacement of current plastics but also offer new application opportunities. Polyhydroxyalkanoates (PHAs) remain a promising candidate for commodity bioplastic production, despite the many decades of efforts by academicians and industrial scientists that have not yet achieved that goal. This article focuses on defining obstacles and solutions to overcome cost-performance metrics that are not sufficiently competitive with current commodity thermoplastics. To that end, this review describes various process innovations that build on fed-batch and semi-continuous modes of operation as well as methods that lead to high cell density cultivations. Also, we discuss work to move from costly to lower cost substrates such as lignocellulose-derived hydrolysates, metabolic engineering of organisms that provide higher substrate conversion rates, the potential of halophiles to provide low-cost platforms in non-sterile environments for PHA formation, and work that uses mixed culture strategies to overcome obstacles of using waste substrates. We also describe historical problems and potential solutions to downstream processing for PHA isolation that, along with feedstock costs, have been an Achilles heel towards the realization of cost-efficient processes. Finally, future directions for efficient PHA production and relevant structural variations are discussed.

Study of Class I and Class III Polyhydroxyalkanoate (PHA) Synthases with Substrates Containing a Modified Side Chain

Polyhydroxyalkanoates (PHAs) are carbon and energy storage polymers produced by a variety of microbial organisms under nutrient-limited conditions. They have been considered as an environmentally friendly alternative to oil-based plastics due to their renewability, versatility, and biodegradability. PHA synthase (PhaC) plays a central role in PHA biosynthesis, in which its activity and substrate specificity are major factors in determining the productivity and properties of the produced polymers. However, the effects of modifying the substrate side chain are not well understood because of the difficulty to accessing the desired analogues. In this report, a series of 3-(R)-hydroxyacyl coenzyme A (HACoA) analogues were synthesized and tested with class I synthases from Chromobacterium sp. USM2 (PhaCCs and A479S-PhaCCs) and Caulobacter crescentus (PhaCCc) as well as class III synthase from Allochromatium vinosum (PhaECAv). It was found that, while different PHA synthases displayed distinct preference with regard to the length of the alkyl side chains, they could withstand moderate side chain modifications such as terminal unsaturated bonds and the azide group. Specifically, the specific activity of PhaCCs toward propynyl analogue (HHxyCoA) was only 5-fold less than that toward the classical substrate HBCoA. The catalytic efficiency (kcat/Km) of PhaECAv toward azide analogue (HABCoA) was determined to be 2.86 × 10(5) M(-1) s(-1), which was 6.2% of the value of HBCoA (4.62 × 10(6) M(-1) s(-1)) measured in the presence of bovine serum albumin (BSA). These side chain modifications may be employed to introduce new material functions to PHAs as well as to study PHA biogenesis via click-chemistry, in which the latter remains unknown and is important for metabolic engineering to produce PHAs economically.

Structural Characterization and Biological Activities of Polysaccharides from Olive Mill Wastewater

Olive mill wastewater (OMWW), the main waste product of olive oil extraction process, was investigated as a source of polysaccharides. The yield of alcohol insoluble residue (AIR) was 20.5 % based on the dry matter of OMWW. Extraction with water gave water soluble (WSF) and insoluble (WIF) fractions from AIR with yields of 13.3 % (w/w) and 3.7 % (w/w) based on the dry matter, respectively. Chemical composition and monosaccharide analysis indicated that glucose was the main monosaccharide of these extracts in addition to galactose, arabinose, rhamnose, and galacturonic acid. Prebiotic and antioxidant activities of polysaccharidic fractions from OMWW were evaluated. Results gave evidence for their scavenging capacity toward the 2,2'-diphenyl-1-picrylhydrazyle (DPPH) (IC50 value of 89.43 μg/mL) and hydroxyl radicals (IC50 value of 158.70 μg/mL), resistance toward artificial human gastric juice, and ability to be fermented by Lactobacilli strains.

Structural basis for enzyme I inhibition by α-ketoglutarate

Creating new bacterial strains in which carbon and nitrogen metabolism are uncoupled is potentially very useful for optimizing yields of microbial produced chemicals from renewable carbon sources. However, the mechanisms that balance carbon and nitrogen consumption in bacteria are poorly understood. Recently, α-ketoglutarate (αKG), the carbon substrate for ammonia assimilation, has been observed to inhibit Escherichia coli enzyme I (EI), the first component of the bacterial phosphotransferase system (PTS), thereby providing a direct biochemical link between central carbon and nitrogen metabolism. Here we investigate the EI-αKG interaction by NMR and enzymatic assays. We show that αKG binds with a KD of ∼2.2 mM at the active site of EI, acting as a competitive inhibitor. In addition, we use molecular docking simulations to derive a structural model of the enzyme-inhibitor complex that is fully consistent with NMR and analytical ultracentrifugation data. We expect that the EI-αKG structure presented here will provide a starting point for structure-based design of EI mutants resistant to αKG.

α-Ketoglutarate coordinates carbon and nitrogen utilization via enzyme I inhibition

Microbes survive in a variety of nutrient environments by modulating their intracellular metabolism. Balanced growth requires coordinated uptake of carbon and nitrogen, the primary substrates for biomass production. The mechanisms that balance carbon and nitrogen uptake are, however, poorly understood. We find in Escherichia coli that a sudden increase in nitrogen availability results in an almost immediate increase in glucose uptake. The concentrations of known glycolytic intermediates and regulators, however, remain homeostatic. Instead, we find that α-ketoglutarate, which accumulates in nitrogen limitation, directly blocks glucose uptake by inhibiting Enzyme I, the first step of the phosphotransferase system (PTS). This enables rapid modulation of glycolytic flux without marked concentration changes in glycolytic intermediates by simultaneously accelerating glucose import and consumption of the terminal glycolytic intermediate phosphoenolpyruvate. Quantitative modeling shows that this previously unidentified regulatory connection is in principle sufficient to coordinate carbon and nitrogen utilization.

High-Cell-Density Cyclic Fed-Batch Fermentation of a Poly(3-Hydroxybutyrate)-Accumulating Thermophile, Chelatococcus sp. Strain MW10

Different fermentation strategies were employed for the cultivation of a new poly(3-hydroxybutyrate)-accumulating thermophilic bacterium, Chelatococcus sp. strain MW10, with the aim of achieving high-cell-density (HCD) growth and high poly(3-hydroxybutyrate) [poly(3HB)] productivity. Enhanced cultivation was achieved by a cyclic fed-batch fermentation (CFBF) technique (42-liter scale). Maximal poly(3HB) productivity was obtained during the second cycle [16.8 ± 4.2 g poly(3HB)/liter]. At the end of CFBF (265 h), an HCD of up to 115.0 ± 4.3 g cell dry weight/liter was achieved.

Poly(3-hydroxybutyrate) production from glycerol by Zobellella denitrificans MW1 via high-cell-density fed-batch fermentation and simplified solvent extraction

Industrial production of biodegradable polyesters such as polyhydroxyalkanoates is hampered by high production costs, among which the costs for substrates and for downstream processing represent the main obstacles. Inexpensive fermentable raw materials such as crude glycerol, an abundant by-product of the biodiesel industry, have emerged to be promising carbon sources for industrial fermentations. In this study, Zobellella denitrificans MW1, a recently isolated bacterium, was used for the production of poly(3-hydroxybutyrate) (PHB) from glycerol as the sole carbon source. Pilot-scale fermentations (42-liter scale) were conducted to scale up the high PHB accumulation capability of this strain. By fed-batch cultivation, at first a relatively high cell density (29.9 +/- 1.3 g/liter) was obtained during only a short fermentation period (24 h). However, the PHB content was relatively low (31.0% +/- 4.2% [wt/wt]). Afterwards, much higher concentrations of PHB (up to 54.3 +/- 7.9 g/liter) and higher cell densities (up to 81.2 +/- 2.5 g/liter) were obtained by further fed-batch optimization in the presence of 20 g/liter NaCl, with optimized feeding of glycerol and ammonia to support both cell growth and polymer accumulation over a period of 50 h. A high specific growth rate (0.422/h) and a short doubling time (1.64 h) were attained. The maximum PHB content obtained was 66.9% +/- 7.6% of cell dry weight, and the maximum polymer productivity and substrate yield coefficient were 1.09 +/- 0.16 g/liter/h and 0.25 +/- 0.04 g PHB/g glycerol, respectively. Furthermore, a simple organic solvent extraction process was employed for PHB recovery during downstream processing: self-flotation of cell debris after extraction of PHB with chloroform allowed a convenient separation of a clear PHB-solvent solution from the cells. Maximum PHB recovery (85.0% +/- 0.10% [wt/wt]) was reached after 72 h of extraction with chloroform at 30 degrees C, with a polymer purity of 98.3% +/- 1.3%.

Engineering the monomer composition of polyhydroxyalkanoates synthesized in Saccharomyces cerevisiae

Polyhydroxyalkanoates (PHAs) have received considerable interest as renewable-resource-based, biodegradable, and biocompatible plastics with a wide range of potential applications. We have engineered the synthesis of PHA polymers composed of monomers ranging from 4 to 14 carbon atoms in either the cytosol or the peroxisome of Saccharomyces cerevisiae by harnessing intermediates of fatty acid metabolism. Cytosolic PHA production was supported by establishing in the cytosol critical beta-oxidation chemistries which are found natively in peroxisomes. This platform was utilized to supply medium-chain (C6 to C14) PHA precursors from both fatty acid degradation and synthesis to a cytosolically expressed medium-chain-length (mcl) polymerase from Pseudomonas oleovorans. Synthesis of short-chain-length PHAs (scl-PHAs) was established in the peroxisome of a wild-type yeast strain by targeting the Ralstonia eutropha scl polymerase to the peroxisome. This strain, harboring a peroxisomally targeted scl-PHA synthase, accumulated PHA up to approximately 7% of its cell dry weight. These results indicate (i) that S. cerevisiae expressing a cytosolic mcl-PHA polymerase or a peroxisomal scl-PHA synthase can use the 3-hydroxyacyl coenzyme A intermediates from fatty acid metabolism to synthesize PHAs and (ii) that fatty acid degradation is also possible in the cytosol as beta-oxidation might not be confined only to the peroxisomes. Polymers of even-numbered, odd-numbered, or a combination of even- and odd-numbered monomers can be controlled by feeding the appropriate substrates. This ability should permit the rational design and synthesis of polymers with desired material properties.

Microbial Synthesis of Poly(3-hydroxyalkanoates) by Pseudomonas aeruginosa from Fatty Acids: Identification of Higher Monomer Units and Structural Characterization

Pseudomonas aeruginosa ATCC 27853 accumulated poly(3-hydroxyalkanoates) (PHAs) after growth on saturated fatty acids with an odd number of carbon atoms. No nutrient limitation was required to induce PHA synthesis, although better yields were obtained when the medium was magnesium deprived. A comparative study was carried out between PHAs obtained from C-odd and those from C-even carbon sources. Repeating units identification was performed by gas chromatography (GC) and capillary liquid chromatography-electrospray mass spectrometry (LC-ESI MS) of methanolyzed samples. When C-odd n-alkanoic acids from nonanoic to pentadecanoic were used the lowest hydroxyalkanoate unit found was 3-hydroxyvalerate and the highest 3-hydroxypentadecanoate, whereas when C-even acids from octanoic to eicosanoic were used these were 3-hydroxycaproate and 3-hydroxyeicosanoate, respectively. Weight average molecular weights were in the range 187 000-596 000. DSC traces showed Tm and DeltaHm which varied from 43 to 58 degrees C and from 5.9 to 24.8 J/g, with the PHAs generated from C-odd carbon sources having lower values. ESI MS of partially pyrolyzed samples allowed the identification of oligomers up to heptamers, and statistical analysis of the ions intensity in the mass spectra showed that these PHAs are random copolyesters.

Bioplastics from microorganisms

The term 'biomaterials' includes chemically unrelated products that are synthesised by microorganisms (or part of them) under different environmental conditions. One important family of biomaterials is bioplastics. These are polyesters that are widely distributed in nature and accumulate intracellularly in microorganisms in the form of storage granules, with physico-chemical properties resembling petrochemical plastics. These polymers are usually built from hydroxy-acyl-CoA derivatives via different metabolic pathways. Depending on their microbial origin, bioplastics differ in their monomer composition, macromolecular structure and physical properties. Most of them are biodegradable and biocompatible, which makes them extremely interesting from the biotechnological point of view.