Biochemical engineering aspects of solid state bioprocessing

The source, activity influencing factors and biological activities for future development of chitin deacetylase

Chitin deacetylase (CDA), a prominent member of the carbohydrate esterase enzyme family 4 (CE4), is found ubiquitously in bacteria, fungi, insects, and crustaceans. This metalloenzyme plays a pivotal role in recognizing and selectively removing acetyl groups from chitin, thus offering an environmentally friendly and biologically-driven preparation method for chitosan with immense industrial potential. Due to its diverse origins, CDAs sourced from different organisms exhibit unique functions, optimal pH ranges, and temperature preferences. Furthermore, certain organic reagents can induce structural changes in CDAs, influencing their catalytic activity. Leveraging CDA's capabilities extends beyond chitosan biocatalysis, as it demonstrates promising application value in agricultural pest control. In this paper, the source, reaction mechanism, influencing factors, the fermentation methods and applications of CDA are reviewed, which provides theoretical help for the research and application of CDA.

Application of solid-state fermentation by microbial biotechnology for bioprocessing of agro-industrial wastes from 1970 to 2020: A review and bibliometric analysis

This paper reviews the pertinent literature from 1970 to 2020 and presents a bibliometric analysis of research trends in the application of solid-state fermentation in the bioprocessing of agro-industrial wastes. A total 5630 publications of studies on solid-state fermentation that comprised of 5208 articles (92.50%), 340 book chapters (6.04%), 39 preprints (0.69%), 32 proceedings (0.56%), 8 edited books (0.14%) and 3 monographs (0.05%) were retrieved from Dimensions database. A review of the literature indicated that (i) fermentation of solid substrates is variously defined in the literature over the past 50 years, where "solid-state fermentation" is the most dominant research term used, and (ii) key products derived from the valorization of agro-industrial wastes through solid-state fermentation include, among others, enzymes, antioxidants, animal feed, biofuel, organic acids, biosurfactants, etc. Bibliometric analyses with VOSviewer revealed an astronomic increase in publications between 2000 and 2020, and further elucidated the most frequently explored core research topics, the most highly cited publications and authors, and countries/regions with the highest number of citations. The most cited publication between 2010 and 2020 had 382 citations compared to 725 citations for the most cited publication from 1970 to 2020. Ashok Pandey from India was the most published and cited author with 123 publications and 8,613 citations respectively; whereas Bioresource Technology was the most published and cited journal with 233 publications and 12,394 citations. Countries with the most publications and citations are Brazil, France, India, and Mexico. These findings suggest that research in the application of solid-state fermentation for bioprocessing of agro-industrial wastes has gained prominence over the past 50 years. Future perspectives and implications are discussed.

Polyurethane foam as an inert support using concentrated media improves quality and spore production from Bacillus thuringiensis

Bacillus thuringiensis (Bt) (Bacillales:Bacillaceae) is a gram-positive bacterium that produces spores, several virulence factors and insecticidal toxins, making this microorganism the most used biopesticide worldwide. The use of inert supports such as polyurethane foam (PUF) in solid cultures has been a great alternative to produce various metabolites, including those produced by Bt. In this study we compared the yields, productivity and quality of the spores by two wild strains of Bt, (Y15 and EA3), grown in media with high substrate concentration in both culture systems: liquid and solid (PUF as solid inert support). Both strains showed 2.5- to 30-fold increases in spore production and productivity in solid culture, which showed an even greater increase when considering the spores retained in the PUF observed by scanning electron microscopy. Moreover, spore produced in solid culture showed up to sevenfold higher survival after a heat-shock treatment, relative to spores from liquid culture. The infectivity against larvae of Galleria mellonella (Lepidoptera:Pyralidae) improved also in spores from solid cultures. This comparison showed that the culture of Bt on solid support has clear advantages over liquid culture in terms of the production and quality of spores, and that those advantages can be attributed only to the culture system, as the same media composition was used in both systems.

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.

Aroma compounds production by solid state fermentation, importance of in situ gas-phase recovery systems

Flavour and fragrance compounds are extremely important for food, feed, cosmetic and pharmaceutical industries. In the last decades, due to the consumer's increased trend towards natural products, a great interest in natural aroma compounds has arisen to the detriment of chemically synthesised ones. Recently, solid state fermentation (SSF) has been applied in the production of many metabolites. Aroma compounds can be produced by SSF with a higher yield compared to submerged fermentation (SmF). In SSF processes, aroma compounds can be produced in the solid matrix or in the headspace, but they can be lost or stripped when aeration is required. This review focuses on the production of aroma compounds by SSF processes with a special highlight on in situ systems to recover the volatiles released in the gaseous phase and stripped due to aeration. Following a brief presentation of specificities of SSF processes concerning the choice of microorganisms and the solid matrix used for the production of aroma compounds, bioreactor aspects, factors affecting production of aroma compounds and in situ gas phase aroma recovery systems in aerated SSF bioreactors are discussed.

By-products from the biodiesel chain as a substrate to citric acid production by solid-state fermentation

In this study, we propose the use of tung cake for the production of organic acids, with an emphasis on citric acid by solid-state fermentation. We evaluated the conditions of production and the by-products from the biodiesel chain as raw materials involved in this bioprocess. First, we standardized the conditions of solid-state fermentation in tung cake with and without residual fat and with different concentrations of glycerine using the fungus Aspergillus niger The solid-state fermentation process was monitored for 7 days considering the biomass growth and pH level. Citric acid production was determined by high-performance liquid chromatography. Fungal development was better in the crude tung cake, consisting of 20% glycerine. The highest citric acid yield was 350 g kg(-1) of biomass. Therefore, the solid-state fermentation of the tung cake with glycerine led to citric acid production using the Aspergillus niger fungus.

Influence of pH regulation and nutrient content on cephalosporin C production in solid-state fermentation by Acremonium chrysogenum C10

AIMS

To investigate the effect of pH regulation and nutrient concentration on cephalosporin C (CPC) production in solid-state fermentation (SSF), using sugarcane bagasse as inert support, impregnated with liquid medium.

METHODS AND RESULTS

Solid-state fermentation using different initial pH values, buffer and nutrient concentrations were performed. Results revealed pH as a key parameter in CPC SSF, as it hampered the antibiotic production not only above 7.8, but also under 6.4. Using initial pH lower than 6.8 and PB in the solid medium, it was possible to keep pH within the production range, increase the production period (from 1 to 3 days) and hence the CPC yield from 468 to 3200 microg gdm(-1) (g(-1) of dry matter).

CONCLUSION

Parameters that help to keep pH in adequate values for CPC production in SSF, such as initial pH, buffering system and nutrient concentration, can greatly increase the production time and CPC yields in this fermentation technique.

SIGNIFICANCE AND IMPACT OF THE STUDY

This is the first work on CPC production on impregnated support, and the only one revealing pH as a key parameter; it is also shown that high nutrient concentration can improve CPC yields in SSF as long as pH is kept under control.

Analysis of expressed sequence tags from the fungus Aspergillus oryzae cultured under different conditions

We performed random sequencing of cDNAs from nine biologically or industrially important cultures of the industrially valuable fungus Aspergillus oryzae to obtain expressed sequence tags (ESTs). Consequently, 21 446 raw ESTs were accumulated and subsequently assembled to 7589 non-redundant consensus sequences (contigs). Among all contigs, 5491 (72.4%) were derived from only a particular culture. These included 4735 (62.4%) singletons, i.e. lone ESTs overlapping with no others. These data showed that consideration of culture grown under various conditions as cDNA sources enabled efficient collection of ESTs. BLAST searches against the public databases showed that 2953 (38.9%) of the EST contigs showed significant similarities to deposited sequences with known functions, 793 (10.5%) were similar to hypothetical proteins, and the remaining 3843 (50.6%) showed no significant similarity to sequences in the databases. Culture-specific contigs were extracted on the basis of the EST frequency normalized by the total number for each culture condition. In addition, contig sequences were compared with sequence sets in eukaryotic orthologous groups (KOGs), and classified into the KOG functional categories.

Thermal denaturation: is solid-state fermentation really a good technology for the production of enzymes?

The potential for thermal denaturation to cause enzyme losses during solid-state fermentation processes for the production of enzymes was examined, using the protease of Penicillium fellutanum as a model system. The frequency factor and activation energies for the first-order denaturation of this enzyme were determined as 3.447 x 10(59) h(-1) and 364,070 Jmol(-1), respectively. These values were incorporated into a mathematical model of enzyme deactivation, which was used to investigate the consequences of subjecting this protease to temporal temperature profiles reported in the literature for mid-height in a 34 cm high packed-bed bioreactor of 150 mm diameter. In this literature source, temperature profiles were measured for 5, 15 and 25 liters per minute of air and enzyme activities were measured as a function of time. The enzyme activity profiles predicted by the model were distributed similarly, one relative to the other, as had been found in the experimental study, with substantial amounts of denaturation being predicted when the substrate temperature exceeded 40 degrees C, which occurred at the lower two airflow rates. A mathematical model of a well-mixed bioreactor was used to explore the difficulties that would be faced at large scale. It suggests that even with airflows as high as one volume per volume per minute, up to 85% of the enzyme produced by the microorganism can be denatured by the end of the fermentation. This work highlights the extra care that must be taken in scaling up solid-state fermentation processes for the production of thermolabile products.

Use of confocal microscopy to follow the development of penetrative hyphae during growth of Rhizopus oligosporus in an artificial solid-state fermentation system

Two methods were compared for determining the concentration of penetrative biomass during growth of Rhizopus oligosporus on an artificial solid substrate consisting of an inert gel and starch as the sole source of carbon and energy. The first method was based on the use of a hand microtome to make sections of approximately 0.2- to 0.4-mm thickness parallel to the substrate surface and the determination of the glucosamine content in each slice. Use of glucosamine measurements to estimate biomass concentrations was shown to be problematic due to the large variations in glucosamine content with mycelial age. The second method was a novel method based on the use of confocal scanning laser microscopy to estimate the fractional volume occupied by the biomass. Although it is not simple to translate fractional volumes into dry weights of hyphae due to the lack of experimentally determined conversion factors, measurement of the fractional volumes in themselves is useful for characterizing fungal penetration into the substrate. Growth of penetrative biomass in the artificial model substrate showed two forms of growth with an indistinct mass in the region close to the substrate surface and a few hyphae penetrating perpendicularly to the surface in regions further away from the substrate surface. The biomass profiles against depth obtained from the confocal microscopy showed two linear regions on log-linear plots, which are possibly related to different oxygen availability at different depths within the substrate. Confocal microscopy has the potential to be a powerful tool in the investigation of fungal growth mechanisms in solid-state fermentation.

The potential for establishment of axial temperature profiles during solid-state fermentation in rotating drum bioreactors

The mixing and heat transfer phenomena within rotating drum bioreactors (RDBs) used for solid-state fermentation processes are poorly studied. The potential for the establishment of axial temperature gradients within the substrate bed was explored using a heat transfer model. For growth of Aspergillus oryzae on wheat bran within a 24 L RDB with air at a superficial velocity of 0.0023 m s(-1) and 15% relative humidity, the model predicts an axial gradient between the air inlet and outlet of 2 degrees C during rapid growth, compared to experimental axial temperature gradients of between 1 and 4 degrees C. Undesirably high temperatures occur throughout the bed under these operating conditions, but the model predicts that good temperature control can be achieved using humid air (90% relative humidity) at superficial velocities of 1 m s(-1) for a 204 L RDB. For a 2200 L RDB, good temperature control is predicted with superficial velocities as low as 0.4 m s(-1) with the airflow being switched from 90% to 15% relative humidity whenever the temperature at the outlet end of the drum exceeds the optimal temperature for growth. This work suggests that significant axial temperature gradients can arise in those RDBs that lack provision for axial mixing. It is therefore advisable to use angled lifters within RDBs to promote axial mixing.

A two-phase model for water and heat transfer within an intermittently-mixed solid-state fermentation bioreactor with forced aeration

A two-phase dynamic model is developed that describes heat and mass transfer in intermittently-mixed solid-state fermentation bioreactors. The model predicts that in the regions of the bed near the air inlet there can be significant differences in the air and solid temperatures, while in the remainder of the bed the gas and solid phases are much closer to equilibrium, although there can be differences in water activity of around 0.05. The increase in the temperature of the gas as it flows through the bed means that it is impossible to prevent the bed from drying out, even if saturated air is used at the air inlet. The substrate can dry to water activities that severely limit growth, unless the bed is intermittently mixed, with the addition of water to bring the water activity back to the desired value. Under the conditions assumed for the simulation, which was designed to mimic the growth of Aspergillus niger on corn, two mixing events were necessary, one at 17.4 and the other at 27.9 h. Even though such a strategy can minimize the restriction of growth by water-limitation, temperature-limitation remains a problem due to the rapid heating dynamics. The model is obviously a useful tool that can be used to guide scale-up and to test control strategies. Such a model, describing the non-equilibrium situation between the gas and solid phases, has not previously been proposed for solid-state fermentation bioreactors. Models in the literature that assume gas-solid temperature and moisture equilibrium cannot describe the large temperature differences between the gas and solid phase which occur within the bed near the air inlet.