Impact of foaming on surfactin production by Bacillus subtilis : Implications on the development of integrated in situ foam fractionation removal systems

Enhanced low-cost lipopeptide biosurfactant production by Bacillus velezensis from residual glycerin

Biosurfactants (BSFs) are molecules produced by microorganisms from various carbon sources, with applications in bioremediation and petroleum recovery. However, the production cost limits large-scale applications. This study optimized BSFs production by Bacillus velezensis (strain MO13) using residual glycerin as a substrate. The spherical quadratic central composite design (CCD) model was used to standardize carbon source concentration (30 g/L), temperature (34 °C), pH (7.2), stirring (239 rpm), and aeration (0.775 vvm) in a 5-L bioreactor. Maximum BSFs production reached 1527.6 mg/L of surfactins and 176.88 mg/L of iturins, a threefold increase through optimization. Microbial development, substrate consumption, concentration of BSFs, and surface tension were also evaluated on the bioprocess dynamics. Mass spectrometry Q-TOF-MS identified five surfactin and two iturin isoforms produced by B. velezensis MO13. This study demonstrates significant progress on BSF production using industrial waste as a microbial substrate, surpassing reported concentrations in the literature.

A comprehensive review of biosurfactant production and its uses in the pharmaceutical industry

Biosurfactants are naturally occurring, surface-active chemicals generated by microorganisms and have attracted interest recently because of their numerous industrial uses. Compared to their chemical equivalents, they exhibit qualities that include lower toxic levels, increased biodegradable properties, and unique physiochemical properties. Due to these traits, biosurfactants have become attractive substitutes for synthetic surfactants in the pharmaceutical industry. In-depth research has been done in the last few decades, demonstrating their vast use in various industries. This review article includes a thorough description of the various types of biosurfactants and their production processes. The production process discussed here is from oil-contaminated waste, agro-industrial waste, dairy, and sugar industry waste, and also how biosurfactants can be produced from animal fat. Various purification methods such as ultrafiltration, liquid-liquid extraction, acid precipitation, foam fraction, and adsorption are required to acquire a purified product, which is necessary in the pharmaceutical industry, are also discussed here. Alternative ways for large-scale production of biosurfactants using different statistical experimental designs such as CCD, ANN, and RSM are described here. Several uses of biosurfactants, including drug delivery systems, antibacterial and antifungal agents, wound healing, and cancer therapy, are discussed. Additionally, in this review, the future challenges and aspects of biosurfactant utilization in the pharmaceutical industry and how to overcome them are also discussed.

Evaluation of an external foam column for in situ product removal in aerated surfactin production processes

In Bacillus fermentation processes, severe foam formation may occur in aerated bioreactor systems caused by surface-active lipopeptides. Although they represent interesting compounds for industrial biotechnology, their property of foaming excessively during aeration may pose challenges for bioproduction. One option to turn this obstacle into an advantage is to apply foam fractionation and thus realize in situ product removal as an initial downstream step. Here we present and evaluate a method for integrated foam fractionation. A special feature of this setup is the external foam column that operates separately in terms of, e.g., aeration rates from the bioreactor system and allows recycling of cells and media. This provides additional control points in contrast to an internal foam column or a foam trap. To demonstrate the applicability of this method, the foam column was exemplarily operated during an aerated batch process using the surfactin-producing Bacillus subtilis strain JABs24. It was also investigated how the presence of lipopeptides and bacterial cells affected functionality. As expected, the major foam formation resulted in fermentation difficulties during aerated processes, partially resulting in reactor overflow. However, an overall robust performance of the foam fractionation could be demonstrated. A maximum surfactin concentration of 7.7 g/L in the foamate and enrichments of up to 4 were achieved. It was further observed that high lipopeptide enrichments were associated with low sampling flow rates of the foamate. This relation could be influenced by changing the operating parameters of the foam column. With the methodology presented here, an enrichment of biosurfactants with simultaneous retention of the production cells was possible. Since both process aeration and foam fractionation can be individually controlled and designed, this method offers the prospect of being transferred beyond aerated batch processes.

Throughput screening of Bacillus subtilis strains that abundantly secrete surfactin in vitro identifies effective probiotic candidates

Since the prohibition of antibiotics as animal growth promoters, demand for effective probiotic strains has steadily increased. The goal is to maintain productivity and mitigate environmental concerns in the livestock industry. There are many probiotic animal-diet supplements available, over 2,000 products in the Republic of Korea alone, with little explanation about the desirable properties of each probiotic strain. The purpose of this study was to describe the underlying logic and methods used to select two novel strains of probiotic candidates. To economically screen these candidates, the abundance of surfactin secreted was used as an in vitro marker. We used a modified oil-misting method to screen ~2,000 spore-forming bacteria for novel strains of Bacillus subtilis. Of these, 18 strains were initially selected based on the semiquantitative criterion that they secreted more surfactin than B. subtilis ATCC21322 on Luria-Berani (LB) agar plates. The whole genome sequence was determined for two of the 18 strains to verify their identity. A phylogeny of 1,162 orthologous genes, genome contents, and genome organization confirmed them as novel strains. The surfactin profiles produced by these two strains consisted of at least four isoforms similar to standard surfactin and enhanced cellulase activities up to 50%. Four fractionated individual isoforms of surfactin suppressed inflammation induced by lipopolysaccharides. The half-maximal inhibitory concentration (IC50) was about 20 μM for each isoform. Both selected strains were susceptible to seven important antibiotics. Our results implied that an abundant secretion of surfactin was a useful biomarker in vitro and could be utilized for mining probiotic candidates through high-throughput screening of environmental samples.

Bacillus licheniformis: The unexplored alternative for the anaerobic production of lipopeptide biosurfactants?

Microbial biosurfactants have attracted the attention of researchers and companies for the last decades, as they are considered promising candidates to replace chemical surfactants in numerous applications. Although in the last years, considerable advances were performed regarding strain engineering and the use of low-cost substrates in order to reduce their production costs, one of the main bottlenecks is their production at industrial scale. Conventional aerobic biosurfactant production processes result in excessive foaming, due to the use of high agitation and aeration rates necessary to increase dissolved oxygen concentration to allow microbial growth and biosurfactant production. Different approaches have been studied to overcome this problem, although with limited success. A not widely explored alternative is the development of foam-free processes through the anaerobic growth of biosurfactant-producing microorganisms. Surfactin, produced by Bacillus subtilis, is the most widely studied lipopeptide biosurfactant, and the most powerful biosurfactant known so far. Bacillus licheniformis strains produce lichenysin, a lipopeptide biosurfactant which structure is similar to surfactin. However, despite its extraordinary surface-active properties and potential applications, lichenysin has been scarcely studied. According to previous studies, B. licheniformis is better adapted to anaerobic growth than B. subtilis, and could be a good alternative for the anaerobic production of lipopeptide biosurfactants. In this review, the potential and limitations of surfactin and lichenysin production under anaerobic conditions will be analyzed, and the possibility of implementing foam-free processes for lichenysin production, in order to expand the market and applications of biosurfactants in different fields, will be discussed.

Foam Fractionation Methods in Aerobic Fermentation Processes

Inherently occurring foam formation during aerobic fermentations of surface-active compounds can be exploited by fractionating the foam. This also serves as the first downstream processing step for product concentration and is used for in situ product recovery. Compared to other foam prevention methods, it does not interfere with fermentation parameters or alter broth composition. Nevertheless, parameters affecting the foaming behaviour are complex. Therefore, the specific foam fractionation designs need to be engineered for each fermentation individually. This still hinders a widespread industrial application. However, few available commercial approaches demonstrate the applicability of foam columns on an industrial scale. This systematic literature review highlights relevant design aspects and process demands that need to be considered for an application to fermentations and proposes a classification of foam fractionation designs and methods. It further analyses substance-specific characteristics associated with foam fractionation. Finally, solutions for current challenges are presented, and future perspectives are discussed. This article is protected by copyright. All rights reserved.

Bioaugmentation as a green technology for hydrocarbon pollution remediation. Problems and prospects

Environmental pollution mitigation measure involving bioremediation technology is a sustainable intervention for a greener ecosystem biorecovery, especially the obnoxious hydrocarbons, xenobiotics, and other environmental pollutants induced by anthropogenic stressors. Several successful case studies have provided evidence to this paradigm including the putative adoption that the technology is eco-friendly, cost-effective, and shows a high tendency for total contaminants mineralization into innocuous bye-products. The present review reports advances in bioremediation, types, and strategies conventionally adopted in contaminant clean-up. It identified that natural attenuation and biostimulation are faced with notable limitations including the poor remedial outcome under the natural attenuation system and the residual contamination occasion following a biostimulation operation. It remarks that the use of genetically engineered microorganisms shows a potentially promising insight as a prudent remedial approach but is currently challenged by few ethical restrictions and the rural unavailability of the technology. It underscores that bioaugmentation, particularly the use of high cell density assemblages referred to as microbial consortia possess promising remedial prospects thus offers a more sustainable environmental security. The authors, therefore, recommend bioaugmentation for large scale contaminated sites in regions where environmental degradation is commonplace.

New Continuous Process for the Production of Lipopeptide Biosurfactants in Foam Overflowing Bioreactor

In this work, an original culture process in bioreactor named overflowing continuous culture (O-CC) was developed to produce and recover continuously mycosubtilin, a lipopeptide antifungal biosurfactant of major interest. The lipopeptide production was first investigated in shake conical flasks in different culture media [ammonium citrate sucrose (ACS), Difco sporulation medium (DSM), and Landy], followed by a pH condition optimization using 3-(N-morpholino)propanesulfonic acid (MOPS) and 2-(N-morpholino)ethanesulfonic acid (MES) buffered media. A simple theoretical modeling of the biomass evolution combined with an experimental setup was then proposed for O-CC processed in stirred tank reactor at laboratory scale. Seven O-CC experiments were done in modified Landy medium at the optimized pH 6.5 by applying dilution rates comprised between 0.05 and 0.1 h^-1. The O-CC allowed the continuous recovery of the mycosubtilin contained in the foam overflowing out of the reactor, achieving a remarkable in situ product removal superior to 99%. The biomass concentration in the overflowing foam was found to be twofold lower than the biomass concentration in the reactor, relating advantageously this process to a continuous one with biomass feedback. To evaluate its performances regarding the type of lipopeptide produced, the O-CC process was tested with strain BBG116, a mycosubtilin constitutive overproducing strain that also produces surfactin, and strain BBG125, its derivative strain obtained by deleting surfactin synthetase operon. At a dilution rate of 0.1 h^-1, specific productivity of 1.18 mg of mycosubtilin⋅g^-1(DW)⋅h^-1 was reached. Compared with other previously described bioprocesses using almost similar culture conditions and strains, the O-CC one allowed an increase of the mycosubtilin production rate by 2.06-fold.

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.

Development of a Bioprocess for the Production of Cyclic Lipopeptides Pseudofactins With Efficient Purification From Collected Foam

Microbial surfactants (biosurfactants) have gained interest as promising substitutes of synthetic surface-active compounds. However, their production and purification are still challenging, with significant room for efficiency and costs optimization. In this work, we introduce a method for the enhanced production and purification of cyclic lipopeptides pseudofactins (PFs) from Pseudomonas fluorescens BD5 cultures. The method is directly applicable in a technical scale with the possibility of further upscaling. Comparing to the original protocol for production of PFs (cultures in mineral salt medium in shaken flasks followed by solvent-solvent extraction of PFs), our process offers not only ∼24-fold increased productivity, but also easier and more efficient purification. The new process combines high yield of PFs (∼7.2 grams of PFs per 30 L of working volume), with recovery levels of 80–90% and purity of raw PFs up to 60–70%. These were achieved with an innovative, single-step thermal co-precipitation and extraction of PFs directly from collected foam, as a large amount of PF-enriched foam was produced during the bioprocess. Besides we present a protocol for the selective production of PF structural analogs and their separation with high-performance liquid chromatography. Our approach can be potentially utilized in the efficient production and purification of other lipopeptides of Pseudomonas and Bacillus origin.

Fe Nanoparticles Enhanced Surfactin Production in Bacillus amyloliquefaciens

Surfactin, as one of the most powerful biosurfactants, can be widely applied in agriculture, food, and pharmaceutics. However, low biosynthesis efficiency is the major obstacle in its commercialization. Here, we used nanoparticles to increase the surfactin production in Bacillus amyloliquefaciens MT45 through enhancing the secretion (the key step of surfactin biosynthesis). The results showed that the surfactin titer increased from 4.93 to 7.15 g/L in the flask and from 5.94 to 9.18 g/L in a 7 L bioreactor by adding 5 g/L Fe nanoparticles. They were the highest titers in the reported wild-type strain. Our results indicated that Fe nanoparticles enhanced the expression of genes involved in the biosynthesis of surfactin. Moreover, Fe nanoparticles increased the permeability of cell membranes, resulting in a more efficient secretion of surfactin. This study provides an efficient strategy for increasing the biosynthesis of microbial metabolites and provides new insights into the nanoparticles' impacts on microbes.

Evaluation of various methods of selection of B. subtilis strains capable of secreting surface-active compounds

The aim of the study was the evaluation of a three-step method for the selection of bacterial strains capable of producing surfactin. The procedure consisted of the following steps: 1.blood agar test, 2. measurement of the surface tension (ST) of the medium using the du Nouy method before and after submerged culture, 3. qualitative and quantitative assessment of surfactin by HPLC. Forty five Bacillus subtilis natto strains producing haemolysis zones (≥3mm) were selected. Nineten of them reduced ST of the medium to ≤ 40 mN/m; in six cases, the reduction was as much as 50%. All indicated strains produced surfactin. Positive correlations (p <0.5) between the percentage reduction of ST of the medium and surfactin concentration (r = 0.44), indicate that this parameter is determinant of the ability to synthesize this compound. The blood agar test has been shown to be useful only as a pre-selection criterion for surfactin producers (18 strains selected by this method reduced ST by only ≤30%). The proposed selection strategy proved effective and made it possible to select the BS15 strain that reduced the ST of the medium to 30.56 ± 0.15 mN/m and simultaneously provided a high concentration of surfactin compared to other strains.

New sustainable alternatives to reduce the production costs for surfactin 50 years after the discovery

In 1968, Arima et al. discovered the heptapeptide, known as surfactin, which belongs to a family of lipopeptides. Known for its ability to reduce surface tension, it also has biological activities such as antimicrobial and antiviral. Its non-ribosomal synthesis mechanism was later discovered (1991). Lipopeptides represent an important class of surfactants, which can be applied in many industrial sectors such as food, pharmaceutical, agrochemicals, detergents, and cleaning products. Currently, 75% of the surfactants used in the various industrial sectors are from the petrochemical industry. Nevertheless, there are global current demands (green chemistry concept) to replace the petrochemical products with environmentally friendly products, such as surfactants by biosurfactants. The production biosurfactants still are costly. Thus, an alternative to reduce the production costs is using agro-industrial waste as a culture medium associated with an efficient and scalable purification process. This review puts a light on the agro-industrial residues used to produce surfactin and the techniques used for its recovery.

Effect of media and fermentation conditions on surfactin and iturin homologues produced by Bacillus natto NT-6: LC-MS analysis

Lipopeptides possess excellent broad spectrum antimicrobial activity. Different lipopeptides have their own unique chemical structures, properties and biological activities. Quantitative analysis of the lipopeptides iturin and surfactin and their homologues produced by Bacillus natto NT-6 subjected to different culture media, shaking speed of rotary shaker, and liquid and solid fermentation methods was conducted using LC-MS. For iturins, liquid-state fermentation in Landy medium at a shaking speed of 160 r min^-1 was the most suitable for maximal homologue production. Addition of 0.4% attapulgite powder increased production by 1.92-fold; activated carbon significantly reduced production. For surfactin homologues, solid-state fermentation in potato dextrose broth medium at shaking speed > 160 r min^-1 was the best. Addition of 0.4% attapulgite powder increased production by 1.96-fold; activated carbon had no effect. Thus it is clear that fermentation conditions can be manipulated to maximize iturin and surfactin production.

Bioactive Secondary Metabolites from Bacillus subtilis: A Comprehensive Review

Bacillus subtilis is widely underappreciated for its inherent biosynthetic potential. This report comprehensively summarizes the known bioactive secondary metabolites from B. subtilis and highlights potential applications as plant pathogen control agents, drugs, and biosurfactants. B. subtilis is well known for the production of cyclic lipopeptides exhibiting strong surfactant and antimicrobial activities, such as surfactins, iturins, and fengycins. Several polyketide-derived macrolides as well as nonribosomal peptides, dihydroisocoumarins, and linear lipopeptides with antimicrobial properties have been reported, demonstrating the biosynthetic arsenal of this bacterium. Promising efforts toward the application of B. subtilis strains and their natural products in areas of agriculture and medicine are underway. However, industrial-scale availability of these compounds is currently limited by low fermentation yields and challenging accessibility via synthesis, necessitating the development of genetically engineered strains and optimized cultivation processes. We hope that this review will attract renewed interest in this often-overlooked bacterium and its impressive biosynthetic skill set.

Evaluation of surfactin synthesis in a genome reduced Bacillus subtilis strain

Strain engineering is often a method of choice towards increasing the yields of the biosurfactant surfactin which is naturally synthesized by many Bacillus spp., most notably Bacillus subtilis. In the current study, a genome reduced B. subtilis 168 strain lacking 10% of the genome was established and tested for its suitability to synthesize surfactin under aerobic and anaerobic conditions at 25 °C, 30 °C, 37 °C and 40 °C. This genome reduced strain was named IIG-Bs20-5-1 and lacks, amongst others, genes synthesizing the lipopeptide plipastatin, the antibiotic bacilysin, toxins and prophages, as well as genes involved in sporulation. Amongst all temperatures tested, 37 °C was overall superior. In comparison to the reference strain JABs24, a surfactin synthesizing variant of B. subtilis 168, strain IIG-Bs20-5-1 was both aerobically and anaerobically superior with respect to specific growth rates µ and yields Y_X/S. However, in terms of surfactin production, strain JABs24 reached higher absolute concentrations with up to 1147.03 mg/L and 296.37 mg/L under aerobic and anaerobic conditions, respectively. Concomitant, strain JABs24 reached higher Y_P/S and Y_P/X. Here, an outstanding Y_P/X of 1.541 g/g was obtained under anaerobic conditions at 37 °C. The current study indicates that the employed genome reduced strain IIG-Bs20-5-1 has several advantages over the strain JABs24 such as better conversion from glucose into biomass and higher growth rates. However, regarding surfactin synthesis and yields, the strain was overall inferior at the investigated temperatures and oxygen conditions. Further studies addressing process development and strain engineering should be performed combining the current observed advantages of the genome reduced strain to increase the surfactin yields and to construct a tailor-made genome reduced strain to realize the theoretically expected advantages of such genome reduced strains.

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.