Cells Were a More Important Foaming Factor than Free Rhamnolipids in Fermentation of Pseudomonas aeruginosa E03-40 for High Rhamnolipid Production

Bacterial-derived surfactants: an update on general aspects and forthcoming applications

The search for sustainable alternatives to the production of chemicals using renewable substrates and natural processes has been widely encouraged. Microbial surfactants or biosurfactants are surface-active compounds synthesized by fungi, yeasts, and bacteria. Due to their great metabolic versatility, bacteria are the most traditional and well-known microbial surfactant producers, being Bacillus and Pseudomonas species their typical representatives. To be successfully applied in industry, surfactants need to maintain stability under the harsh environmental conditions present in manufacturing processes; thus, the prospection of biosurfactants derived from extremophiles is a promising strategy to the discovery of novel and useful molecules. Bacterial surfactants show interesting properties suitable for a range of applications in the oil industry, food, agriculture, pharmaceuticals, cosmetics, bioremediation, and more recently, nanotechnology. In addition, they can be synthesized using renewable resources as substrates, contributing to the circular economy and sustainability. The article presents a general and updated review of bacterial-derived biosurfactants, focusing on the potential of some groups that are still underexploited, as well as, recent trends and contributions of these versatile biomolecules to circular bioeconomy and nanotechnology.

Achieving “Non-Foaming” Rhamnolipid Production and Productivity Rebounds of Pseudomonas aeruginosa under Weakly Acidic Fermentation

The rhamnolipid production of Pseudomonas aeruginosa has been impeded by its severe foaming; overcoming the bottleneck of foaming has become the most urgent requirement for rhamnolipid production in recent decades. In this study, we performed rhamnolipid fermentation under weakly acidic conditions to address this bottleneck. The results showed that the foaming behavior of rhamnolipid fermentation broths was pH-dependent with the foaming ability decreasing from 162.8% to 28.6% from pH 8 to 4. The “non-foaming” rhamnolipid fermentation can be realized at pH 5.5, but the biosynthesis of rhamnolipids was significantly inhibited. Further, rhamnolipid yield rebounded from 8.1 g/L to 15.4 g/L after ultraviolet and ethyl methanesulfonate compound mutagenesis. The mechanism study showed that the species changes of rhamnolipid homologs did not affect the foaming behavior of the fermentation but had a slight effect on the bioactivity of rhamnolipids. At pH 8.0 to 5.0, increased surface tension, decreased viscosity and zeta potential, and aggregation of rhamnolipid molecules contributed to the “non-foaming” rhamnolipid fermentation. This study provides a promising avenue for the “non-foaming” rhamnolipid fermentation and elucidates the mechanisms involved, facilitating the understanding of pH-associated foaming behavior and developing a more efficient strategy for achieving rhamnolipid production.

Foaming of rhamnolipids fermentation: impact factors and fermentation strategies

Rhamnolipids have recently attracted considerable attentions because of their excellent biosurfactant performance and potential applications in agriculture, environment, biomedicine, etc., but severe foaming causes the high cost of production, restraining their commercial production and applications. To reduce or eliminate the foaming, numerous explorations have been focused on foaming factors and fermentation strategies, but a systematic summary and discussion are still lacking. Additionally, although these studies have not broken through the bottleneck of foaming, they are conducive to understanding the foaming mechanism and developing more effective rhamnolipids production strategies. Therefore, this review focuses on the effects of fermentation components and control conditions on foaming behavior and fermentation strategies responded to the severe foaming in rhamnolipids fermentation and systematically summarizes 6 impact factors and 9 fermentation strategies. Furthermore, the potentialities of 9 fermentation strategies for large-scale production are discussed and some further strategies are suggested. We hope this review can further facilitate the understanding of foaming factors and fermentation strategies as well as conducive to developing the more effective large-scale production strategies to accelerate the commercial production process of rhamnolipids.

Uncoupling Foam Fractionation and Foam Adsorption for Enhanced Biosurfactant Synthesis and Recovery

The production of biosurfactants is often hampered by excessive foaming in the bioreactor, impacting system scale-up and downstream processing. Foam fractionation was proposed to tackle this challenge by combining in situ product removal with a pre-purification step. In previous studies, foam fractionation was coupled to bioreactor operation, hence it was operated at suboptimal parameters. Here, we use an external fractionation column to decouple biosurfactant production from foam fractionation, enabling continuous surfactant separation, which is especially suited for system scale-up. As a subsequent product recovery step, continuous foam adsorption was integrated into the process. The configuration is evaluated for rhamnolipid (RL) or 3-(3-hydroxyalkanoyloxy)alkanoic acid (HAA, i.e., RL precursor) production by recombinant non-pathogenic Pseudomonas putida KT2440. Surfactant concentrations of 7.5 g_RL/L and 2.0 g_HAA/L were obtained in the fractionated foam. 4.7 g RLs and 2.8 g HAAs could be separated in the 2-stage recovery process within 36 h from a 2 L culture volume. With a culture volume scale-up to 9 L, 16 g RLs were adsorbed, and the space-time yield (STY) increased by 31% to 0.21 gRL/L·h. We demonstrate a well-performing process design for biosurfactant production and recovery as a contribution to a vital bioeconomy.

Genetic Cell-Surface Modification for Optimized Foam Fractionation

Rhamnolipids are among the glycolipids that have been investigated intensively in the last decades, mostly produced by the facultative pathogen Pseudomonas aeruginosa using plant oils as carbon source and antifoam agent. Simplification of downstream processing is envisaged using hydrophilic carbon sources, such as glucose, employing recombinant non-pathogenic Pseudomonas putida KT2440 for rhamnolipid or 3-(3-hydroxyalkanoyloxy)alkanoic acid (HAA, i.e., rhamnolipid precursors) production. However, during scale-up of the cultivation from shake flask to bioreactor, excessive foam formation hinders the use of standard fermentation protocols. In this study, the foam was guided from the reactor to a foam fractionation column to separate biosurfactants from medium and bacterial cells. Applying this integrated unit operation, the space-time yield (STY) for rhamnolipid synthesis could be increased by a factor of 2.8 (STY = 0.17 gRL/L·h) compared to the production in shake flasks. The accumulation of bacteria at the gas-liquid interface of the foam resulted in removal of whole-cell biocatalyst from the reactor with the strong consequence of reduced rhamnolipid production. To diminish the accumulation of bacteria at the gas-liquid interface, we deleted genes encoding cell-surface structures, focusing on hydrophobic proteins present on P. putida KT2440. Strains lacking, e.g., the flagellum, fimbriae, exopolysaccharides, and specific surface proteins, were tested for cell surface hydrophobicity and foam adsorption. Without flagellum or the large adhesion protein F (LapF), foam enrichment of these modified P. putida KT2440 was reduced by 23 and 51%, respectively. In a bioreactor cultivation of the non-motile strain with integrated rhamnolipid production genes, biomass enrichment in the foam was reduced by 46% compared to the reference strain. The intensification of rhamnolipid production from hydrophilic carbon sources presented here is an example for integrated strain and process engineering. This approach will become routine in the development of whole-cell catalysts for the envisaged bioeconomy. The results are discussed in the context of the importance of interacting strain and process engineering early in the development of bioprocesses.

Recent advancements in the production of rhamnolipid biosurfactants by Pseudomonas aeruginosa

Rhamnolipid (RL) biosurfactant which is produced by Pseudomonas species is one of the most effective surface-active agents investigated in the literature. Over the years, many efforts have been made and an array of techniques has been developed for the isolation of RL produced strains as well as RL homolog characterization. Reports show that RL productivity by the best-known producer, Pseudomonas aeruginosa, is very diverse, from less than 1 gr/l to more than 200 g L-1. There are some major parameters that can affect RL productivity. These are culture conditions, medium composition, the mode of operation (batch, fed-batch and continuous), bioengineering/gene manipulation and finally extraction methods. The present paper seeks to provide a comprehensive overview on the production of rhamnolipid biosurfactant by different species of Pseudomonas bacteria. In addition, we have extensively reviewed their potential for possible future applications.

Recent progress and trends in the analysis and identification of rhamnolipids

Rhamnolipids have extensive potential applications and are the most promising biosurfactants for commercialization. The efficient and accurate identification and analysis of these are important to their production, application and commercialization. Accordingly, significant efforts have been made to identify and analyse rhamnolipids during screening of producing strains, fermentation and application processes. Cationic cetyltrimethylammonium bromide-methylene blue (CTAB-MB) test combines a series of indirect assays to efficiently assist in the primary screening of rhamnolipids-producing strains, while the secretion of rhamnolipids by these strains can be identified through TLC, FTIR, NMR, electrospray ionization mass spectrometry (ESI-MS) and HPLC-MS analysis. Rhamnolipids can be quantified by colorimetric methods requiring the use of concentrated acid, and this approach has the advantages of reliability, simplicity, low-cost and excellent reproducibility with very low technological requirements. HPLC-MS can also be employed as required as a more accurate quantification method. In addition, HPLC-ELSD has been established as the internationally acceptable measure of rhamnolipids for commercial purposes. The preparation of well-accepted rhamnolipids standards and modifications of analysis operations are essential to further enhance the accuracy and improve the simplicity of rhamnolipid analysis.Key points• Current status of R&D works on determination of rhamnolipids is listed• Advantages and disadvantages of various types analysis are summarized• Limitations of current rhamnolipid quantification are discussed Graphical abstract.

Enhanced rhamnolipids production using a novel bioreactor system based on integrated foam-control and repeated fed-batch fermentation strategy

BACKGROUND

Rhamnolipids are the best known microbial-derived biosurfactants, which has attracted great interest as potential ''green" alternative for synthetic surfactants. However, rhamnolipids are the major contributors to severe foam problems, which greatly inhibit the economics of industrial-scale production. In this study, a novel foam-control system was established for ex situ dealing with the massive overflowing foam. Based on the designed facility, foam reduction efficiency, rhamnolipids production by batch and repeated fed-batch fermentation were comprehensively investigated.

RESULTS

An ex situ foam-control system was developed to control the massive overflowing foam and improve rhamnolipids production. It was found that the size of individual bubble in the early stage was much larger than that of late fermentation stage. The foam liquefaction efficiency decreased from 54.37% at the beginning to only 9.23% at the end of the fermentation. This difference of bubble stability directly resulted in higher foam reduction efficiency of 67.46% in the early stage, whereas the small uniform bubbles can only be reduced by 57.53% at the later fermentation stage. Moreover, reduction of secondary foam is very important for foam controlling. Two improved designs of the device in this study obtained about 20% improvement of foam reduction efficiency, respectively. The batch fermentation result showed that the average volume of the overflowing foam was reduced from 58-640 to 19-216 mL/min during the fermentation process, presenting a notable reduction efficiency ranging from 51.92 to 73.47%. Meanwhile, rhamnolipids production of batch fermentation reached 45.63 g/L, and the yield 0.76 g/g was significantly better than ever reported. Further, a repeated fed-batch fermentation based on the overall optimization was carried out. Total rhamnolipids concentration reached 48.67 g/L with the yield around of 0.67-0.83 g/g, which presented an improvement of 62% and 49% compared with conventional batch fermentation by using various kinds of defoamers, respectively.

CONCLUSIONS

The ex situ foam-control system presented a notable reduction efficiency, which helped greatly to easily solve the severe foaming problem without any defoamer addition. Moreover, rhamnolipids production and yield by repeated fed-batch fermentation obtained prominent improvement compared to conventional batch cultivation, which can further facilitate economical rhamnolipids production at large scales.

Recent progress towards industrial rhamnolipids fermentation: Process optimization and foam control

The global market for rhamnolipids production holds great promise, and is in need of an economically viable mass-production scheme. Accordingly, several strategies have been employed to improve the efficiency of rhamnolipid production in the past few decades. Currently, rhamnolipids can be produced by Pseudomonas aeruginosa at a high yield (over 70 g/L) when vegetable oil is used as the carbon source under optimized fed-batch cultivations. However, severe foaming during rhamnolipid fermentation inhibits scaling-up and production efficiency. Stop valve was found to effective break the extremely stable rhamnolipids foams during fermentation, and production efficiency of rhamnolipids was highly improved, while its scale-up mechanism needs further study. In addition, the combination of both chemical and mechanical approaches is likely to be more efficiently resolving the foam problem existed in rhamnolipids fermentation than either chemical or mechanical methods alone.

Rhamnolipid production by a gamma ray-induced Pseudomonas aeruginosa mutant under solid state fermentation

Solid-state fermentation has a special advantage of preventing the foaming problem that obstructs submerged fermentation processes for rhamnolipid production. In the present work, a 50:50 mixture of sugarcane bagasse and sunflower seed meal was selected as the optimum substrate for rhamnolipid production using a Pseudomonas aeruginosa mutant 15GR and an impregnating solution including 5% v/v glycerol. Using Box-Behnken design, the optimum fermentation conditions were found to be an inoculum size 1% v/v, temperature 30 °C and unlike other studies, pH 8. These optimized conditions yielded a 67% enhancement of rhamnolipid levels reaching 46.85 g rhamnolipids per liter of impregnating solution, after 10 days, which was about 5.5 folds higher than that obtained by submerged liquid fermentation. Although maximum rhamnolipids concentration was obtained after 10 days of incubation, rhamnolipids concentration already reached high levels (41.87 g/l) after only 6 days. This rhamnolipid level was obtained in a shorter time and using lower carbon source concentrations than most studies reported so far. The findings obtained indicate an enormous potential for employing solid-state fermentation for rhamnolipid production by the studied isolate.

Production of rhamnolipids by integrated foam adsorption in a bioreactor system

Biosurfactants offer environmental as well as health benefits over traditionally used chemical surfactants and heterologous production from engineered microorganisms has been demonstrated, offering containable as well as scalable production of these alternative chemicals. Low product titers and cost intensive downstream processing are the main hurdles for economical biosurfactant production at industrial scales. Increased biosurfactant concentrations are found in the liquid fraction of the foam formed during fermentation of producing microbes. Adsorption of biosurfactants from foam fractions in cultivations may offer a simple concentration and purification method which could enable their cost-effective production. Here, foam adsorption was applied as an in situ method for separation of the rhamnolipid biosurfactants during fermentation of Pseudomonas putida EM383. An integrated process was designed to capture the produced rhamnolipids on hydrophobic adsorbent in packed bed units while minimizing the impact of adsorption on the productivity of the system by recirculating cell-containing collapsed foam flow-through back into the reactor vessel. A stable rhamnolipid production by P. putida EM383 on glucose was performed coupled to this adsorption strategy for 82 h, after which no remaining rhamnolipids were found in the cultivation broth and 15.5 g of rhamnolipids could be eluted from the adsorbent. Rhamnolipid yield from glucose feed was 0.05 g g⁻¹, when up to 2 g L⁻¹ glucose pulse feeding was applied. After solvent evaporation, a product purity of 96% was obtained. The results indicate that the integrated adsorption method can be efficient for simultaneous production and recovery of rhamnolipid biosurfactants from microbial fermentations.

Advances in applications of rhamnolipids biosurfactant in environmental remediation: A review

The objective of this review is to provide a comprehensive overview of the advances in the applications of rhamnolipids biosurfactants in soil and ground water remediation for removal of petroleum hydrocarbon and heavy metal contaminants. The properties of rhamnolipids associated with the contaminant removal, that is, solubilization, emulsification, dispersion, foaming, wetting, complexation, and the ability to modify bacterial cell surface properties, were reviewed in the first place. Then current remediation technologies with integration of rhamnolipid were summarized, and the effects and mechanisms for rhamnolipid to facilitate contaminant removal for these technologies were discussed. Finally rhamnolipid-based methods for remediation of the sites co-contaminated by petroleum hydrocarbons and heavy metals were presented and discussed. The review is expected to enhance our understanding on environmental aspects of rhamnolipid and provide some important information to guide the extending use of this fascinating chemical in remediation applications.

Maximize rhamnolipid production with low foaming and high yield

Rhamnolipids are well-known microbial surfactants with many potential applications. Their production cost, however, remains high due to the severe foaming tendency in aerobic fermentation and the relatively low productivity and yield. In this study, we assessed the boundaries set by these constraints after optimization of basic parameters such as dissolved oxygen concentration (DO), pH and carbon sources. DO 10% and pH 5.5-5.7 were found optimal; cell growth and/or rhamnolipid production were slower at lower DO (5%) or pH (5.0) while foaming became hard to control at higher DO (30%) or pH (6.0 and 6.5). Although the Pseudomonas aeruginosa strain used was selected for its high rhamnolipid production from glycerol as substrate, soybean oil was still found to be a better substrate that increased specific rhamnolipid productivity to 25.8mg/g cells-h from the glycerol-supported maximum of 8.9mg/g cells-h. In addition, the foam volume was approximately halved by using soybean oil instead of glycerol as substrate. Analysis by liquid chromatography coupled with mass spectrometry revealed that rhamnolipid compositions from the two carbon sources were also very different, with primarily (82%) monorhamnolipids from soybean oil and more (64%) dirhamnolipids from glycerol. The optimized fermentation produced 42g/l rhamnolipids at a yield of approximately 47% and a volumetric productivity of 220mg/l-h. These values are among the highest reported.

Effects of rhamnolipids on microorganism characteristics and applications in composting: A review

Biosurfactant rhmnolipids have been applied in many fields, especially in environmental bioremediation. According to previous researches, many research groups have studied the influence of rhamnolipids on microorganism characteristics and/or its application in composting. In this review, the effects of rhamnolipids on the cell surface properties of microorganisms was discussed firstly, such as cell surface hydrophobicity (CSH), electrical, surface compounds, etc. Moreover, the deeper mechanisms were also discussed, such as the effects of rhamnolipids on the structural characteristics and functional characteristics of the cell membrane, and the effects of rhamnolipids on the related enzymes and genes. Additionally, the application of rhamnolipids in composting was discussed, which is an important way for pollutant biodegradation and resource reutilization. It is believed that rhamnolipids will play more and more important role in composting.

Rhamnolipid Adsorption in Soil: Factors, Unique Features, and Considerations for Use as Green Antizoosporic Agents

In aqueous solutions, rhamnolipids effectively kill the motile zoospores responsible for spreading many pathogens, including soy-infecting Phytophthora sojae. For use in soil, adsorption properties need to be considered. Having low critical micelle concentrations, rhamnolipids tend to form micelles/aggregates with unknown effects on soil adsorption. Effects of soil pH, rhamnolipid congener structure, and concentration were examined. Congeners were identified and each quantitated for adsorptive partitioning. The adsorption isotherm at pH 6.5 showed a multi-stage profile plateauing at 1700 μg/g of soil. Less hydrophilic congeners adsorbed preferentially: R-C10-C12 > R-C10-C12:1 > RR-C10-C12:1 > RR-C10-C12 > R-C10-C10 > RR-C10-C10 > R-C8-C10 > RR-C8-C10 (where R is rhamnose and C# is the carbon number of β-hydroxy fatty acid). Adsorptive selectivity among congeners was very clear in dilute solutions but diminished with increasing concentrations. Results were interpreted with aggregate formation in solutions and on the soil surface. The cost estimate made accordingly supported the economic feasibility of rhamnolipid antizoosporic uses in soil.