Fed-batch cultivation and adding supplements to increase yields of polyhydroxybutyrate production by Cupriavidus necator from corn stover alkaline pretreatment liquor

Bacterial valorization of lignin for the sustainable production of value-added bioproducts

As the most abundant aromatic biopolymer in the biosphere, lignin represents a promising alternative feedstock for the industrial production of various value-added bioproducts with enhanced economical value. However, the large-scale implementation of lignin valorization remains challenging because of the heterogeneity and irregular structure of lignin. General fragmentation and depolymerization processes often yield various products, but these approaches necessitate tedious purification steps to isolate target products. Moreover, microbial biocatalytic processes, especially bacterial-based systems with high metabolic activity, can depolymerize and further utilize lignin in an eco-friendly way. Considering that wild bacterial strains have evolved several metabolic pathways and enzymatic systems for lignin degradation, substantial efforts have been made to exploit their potential for lignin valorization. This review summarizes recent advances in lignin valorization for the production of value-added bioproducts based on bacterial systems. Additionally, the remaining challenges and available strategies for lignin biodegradation processes and future trends of bacterial lignin valorization are discussed.

From Knallgas Bacterium to Promising Biomanufacturing Host: The Evolution of Cupriavidus necator

The expanding field of synthetic biology requires diversification of microbial chassis to expedite the transition from a fossil fuel-dependent economy to a sustainable bioeconomy. Relying exclusively on established model organisms such as Escherichia coli and Saccharomyces cerevisiae may not suffice to drive the profound advancements needed in biotechnology. In this context, Cupriavidus necator, an extraordinarily versatile microorganism, has emerged as a potential catalyst for transformative breakthroughs in industrial biomanufacturing. This comprehensive book chapter offers an in-depth review of the remarkable technological progress achieved by C. necator in the past decade, with a specific focus on the fields of molecular biology tools, metabolic engineering, and innovative fermentation strategies. Through this exploration, we aim to shed light on the pivotal role of C. necator in shaping the future of sustainable bioprocessing and bioproduct development.

One-pot treatment of Saccharophagus degradans for polyhydroxyalkanoate production from brown seaweed

The conventional production of polyhydroxyalkanoate (PHA) from waste biomass requires a pretreatment step (acid or alkali) for reducing sugar extraction, followed by bacterial fermentation. This study aims to find a greener approach for PHA production from brown seaweed. Saccharophagus degradans can be a promising bacterium for simultaneous reducing sugar and PHA production, bypassing the need for a pretreatment step. Cell retention cultures of S. degradans in membrane bioreactor resulted in approximately 4- and 3-fold higher PHA concentrations than batch cultures using glucose and seaweed as carbon sources, respectively. X-ray diffraction, Fourier transform infrared spectroscopy, and nuclear magnetic resonance results revealed identical peaks for the resulting PHA and standard poly(3-hydroxybutyrate). The developed one step process using cell retention culture of S. degradans could be a beneficial process for scalable and sustainable PHA production.

Recent updates to microbial production and recovery of polyhydroxyalkanoates

The increasing use of synthetic polymers and their disposal has raised concern due to their adverse effects on the environment. Thus, other sustainable alternatives to synthetic plastics have been sought, such as polyhydroxyalkanoates (PHAs), which are promising microbial polyesters, mainly due to their compostable nature, biocompatibility, thermostability, and resilience, making this biopolymer acceptable in several applications in the global market. The large-scale production of PHAs by microorganisms is still limited by the high cost of production compared to conventional plastics. This review reports some strategies mentioned in the literature aimed at production and recovery, paving the way for the bio-based economy. For this, some aspects of PHAs are addressed, such as synthesis, production systems, process control using by-products from industries, and advances and challenges in the downstream. The bioplastics properties made them a prime candidate for food, pharmaceutical, and chemical industrial applications. With this paper, it is possible to see that biodegradable polymers are promising materials, mainly for reducing the pollution produced by polymers derived from petroleum.

Valorization of lignocellulosic biomass for polyhydroxyalkanoate production: Status and perspectives

With the increasing concerns regarding climate, energy, and plastic crises, bio-based production of biodegradable polymers has become a dire necessity. Significant progress has been made in biotechnology for the production of biodegradable polymers from renewable resources to achieve the goal of zero plastic waste and a net-zero carbon bioeconomy. In this review, an overview of polyhydroxyalkanoate (PHA) production from lignocellulosic biomass (LCB) was presented. Having established LCB-based biorefinery with proper pretreatment techniques, various PHAs could be produced from LCB-derived sugars, hydrolysates, and/or aromatic mixtures employing microorganisms. This provides a clue for addressing the current environmental crises because "biodegradable polymers" could be produced from one of the most abundant resources that are renewable and sustainable in a "carbon-neutral process". Furthermore, the potential future of LCB-to-non-natural PHA production was discussed with particular reference to non-natural PHA biosynthesis methods and LCB-derived aromatic mixture biofunnelling systems.

Production of Polyhydroxyalkanoates through Soybean Hull and Waste Glycerol Valorization: Subsequent Alkaline Pretreatment and Enzymatic Hydrolysis

Alkaline pretreatment and sequential enzymatic hydrolysis of soybean hull were investigated to obtain fermentable sugars for polyhydroxyalkanoates production along with residual glycerol as low-cost carbon sources. Soybean hull is composed of approximately 32% cellulose, 12% hemicellulose, 6% lignin, and 11% protein. Alkaline pretreatment was carried out with 2% NaOH concentration, 10% (w/v) biomass loading, and 60 min incubation time in an autoclave at 120 °C. The response surface methodology (RSM) based on the central composite design (CCD) tool was employed to optimize the enzymatic hydrolysis process, where the variables of biomass loading, enzymes’ concentration, and time were considered. The maximum total reducing sugars concentration obtained was 115.9 g∙L−1 with an enzyme concentration of 11.5 mg protein/g dry substrate for enzyme preparation B1, 2.88 mg protein/g dry substrate for XylA, and 57.6 U/g dry substrate for β-glucosidase, after 42 h at 45 °C, and pH was 4.5. Subsequently, the saccharification step was conducted by increasing the processing scale, using a 1 L tank with stirring with a controlled temperature. Implementing the same enzyme concentrations at pH 4.5, temperature of 45 °C, 260 mL working volume, and incubation time of 42 h, under fed-batch operation with substrate feeding after 14 h and 22 h, a hydrolysate with a concentration of 185.7 g∙L−1 was obtained. Initially, to verify the influence of different carbon sources on Cupriavidus necator DSMz 545 in biomass production, batch fermentations were developed, testing laboratory-grade glucose, soybean hull hydrolysate, and waste glycerol (a by-product of biodiesel processing available in large quantities) as carbon sources in one-factor-at-a-time assays, and the mixture of soybean hull hydrolysate and waste glycerol. Then, the hydrolysate and waste glycerol were consumed by C. necator, producing 12.1 g∙L−1 of biomass and achieving 39% of polyhydroxyalkanoate (PHB) accumulation. To the best of our knowledge, this is the first time that soybean hull hydrolysate has been used as a carbon source to produce polyhydroxyalkanoates, and the results suggest that this agro-industrial by-product is a viable alternative feedstock to produce value-added components.

Recent advances in black liquor valorization

Lignocellulosic biomass is projected as a prospective renewable alternative to petroleum for the production of fuel and chemicals. Pretreatment is necessary to disrupt the lignocellulosic structure for extraction of cellulose. Biomass after pretreatment is segregated into cellulose rich solid fraction and black liquor (lignin and hemicelluloses) as a liquid stream. The plant polysaccharide-based industry primarily utilizes the cellulosic fraction as raw material, and carbon rich black liquor discarded as waste or burnt for energy recovery. This review highlights the recent advancements in the biological and chemical valorization of black liquor into fuels and chemicals. The recent research attempted for bioconversion of black liquor into Bioplastic, Biohydrogen, Biogas, and chemicals has been discussed. In addition, the efforts to replace the conventional energy recovery method with the advanced chemical process along with their modifications have been reviewed that will decide the sustainability of the lignocellulosic biomass-based industry.

A critical review for advances on industrialization of immobilized cell Bioreactors: Economic evaluation on cellulose hydrolysis for PHB production

Advances such as cell-on-cell immobilization, multi-stage fixed bed tower (MFBT) bioreactor, promotional effect on fermentation, extremely low temperature fermentation, freeze dried immobilized cells in two-layer fermentation, non-engineered cell factories, and those of recent papers are demonstrated. Studies for possible industrialization of ICB, considering production capacity, low temperatures fermentations, added value products and bulk chemical production are studied. Immobilized cell bioreactors (ICB) using cellulose nano-biotechnology and engineered cells are reported. The development of a novel ICB with recent advances on high added value products and conceptual research areas for industrialization of ICB is proposed. The isolation of engineered flocculant cells leads to a single tank ICB. The concept of cell factories without GMO is a new research area. The conceptual development of multi-stage fixed bed tower membrane (MFBTM) ICB is discussed. Finally, feasible process design and technoeconomic analysis of cellulose hydrolysis using ICB are studied for polyhydroxybutyrate (PHB) production.

A review on polyhydroxyalkanoate production from agricultural waste Biomass: Development, Advances, circular Approach, and challenges

Polyhydroxyalkanoates are biopolymers produced by microbial fermentation. They have excellent biodegradability and biocompatibility, which are regarded as promising substitutes for traditional plastics in various production and application fields. This review details the research progress in PHA production from lignocellulosic crop residues, lipid-type agricultural wastes, and other agro-industrial wastes such as molasses and whey. The effective use of agricultural waste can further reduce the cost of PHA production while avoiding competition between industrial production and food. The latest information on fermentation parameter optimization, fermentation strategies, kinetic studies, and circular approach has also been discussed. This review aims to analyze the crucial process of the PHA production from agricultural wastes to provide support and reference for further scale-up and industrial production.

Control algorithms and strategies of feeding for fed-batch fermentation of Escherichia coli: a review of 40 years of experience

Fed-batch cultivation is a well-known type of submerged fermentation that is frequently used in manufacture of recombinant proteins and various kinds of enzymes, owing to its ability to produce products with high concentrations and high efficiency. In fed-batch culture, several issues must be considered; most of them are also presented in batch culture. However, feed flow rate calculation only corresponds to fed-batch fermentation and its value has a significant impact on productivity, efficiency, final concentration of product, formation of by-products, and viscosity of the culture. From this background, the present review article is an effort to gather the information on feeding strategies for fed-batch cultivation of Escherichia coli, which is a well-known microorganism in the production of recombinant proteins and industrial enzymes, especially for therapeutic applications. Moreover, this review is an aid to comprehend and compare the fundamental concept of different feeding strategies and their advantages and drawbacks.

Chemoautotroph Cupriavidus necator as a potential game-changer for global warming and plastic waste problem: A review

Cupriavidus necator, a versatile microorganism found in both soil and water, can have both heterotrophic and lithoautotrophic metabolisms depending on environmental conditions. C. necator has been extensively examined for producing Polyhydroxyalkanoates (PHAs), the promising polyester alternatives to petroleum-based synthetic polymers because it has a superior ability for accumulating a considerable amount of PHAs from renewable resources. The development of metabolically engineered C. necator strains has led to their application for synthesizing biopolymers, biofuels and biochemicals such as ethanol, isobutanol and higher alcohols. Bio-based processes of recombinant C. necator have made much progress in production of these high-value products from biomass wastes, plastic wastes and even waste gases. In this review, we discuss the potential of C. necator as promising platform host strains that provide a great opportunity for developing a waste-based circular bioeconomy.

Production of PHB From CO2-Derived Acetate With Minimal Processing Assessed for Space Biomanufacturing

Providing life-support materials to crewed space exploration missions is pivotal for mission success. However, as missions become more distant and extensive, obtaining these materials from in situ resource utilization is paramount. The combination of microorganisms with electrochemical technologies offers a platform for the production of critical chemicals and materials from CO₂ and H₂O, two compounds accessible on a target destination like Mars. One such potential commodity is poly(3-hydroxybutyrate) (PHB), a common biopolyester targeted for additive manufacturing of durable goods. Here, we present an integrated two-module process for the production of PHB from CO₂. An autotrophic Sporomusa ovata (S. ovata) process converts CO₂ to acetate which is then directly used as the primary carbon source for aerobic PHB production by Cupriavidus basilensis (C. basilensis). The S. ovata uses H₂ as a reducing equivalent to be generated through electrocatalytic solar-driven H₂O reduction. Conserving and recycling media components is critical, therefore we have designed and optimized our process to require no purification or filtering of the cell culture media between microbial production steps which could result in up to 98% weight savings. By inspecting cell population dynamics during culturing we determined that C. basilensis suitably proliferates in the presence of inactive S. ovata. During the bioprocess 10.4 mmol acetate L ^-1 day^-1 were generated from CO₂ by S. ovata in the optimized media. Subsequently, 12.54 mg PHB L^-1 hour^-1 were produced by C. basilensis in the unprocessed media with an overall carbon yield of 11.06% from acetate. In order to illustrate a pathway to increase overall productivity and enable scaling of our bench-top process, we developed a model indicating key process parameters to optimize.

Evaluation of Fed-Batch Fermentation for Production of Polyhydroxybutyrate With a Banana Pulp Juice Substrate From an Agro Industrial By-Product

Pollution resulting from the persistence of plastics in the environment has driven the development of substitutes for these materials through fermentation processes using agro-industrial wastes. Polyhydroxybutyrate (PHB) is a rapidly biodegradable material with chemical and mechanical properties comparable to those of some petroleum-derived plastics. PHB accumulates intracellularly as an energy reserve in a wide variety of microorganisms exposed to nutritionally imbalanced media. The objective of this study was to evaluate the use of a banana waste product as a carbon source for PHB production. PHB was extracted by acid methanolysis and detected by gas chromatography-mass spectrometry. Eleven bacterial strains with potential for PHB production were evaluated by in vitro fermentation in a culture broth containing fructose as the carbon source and limited nitrogen. A 22 central composite rotational design was applied to optimize the concentrations of banana juice and ammonium chloride needed to maximize the PHB-producing biomass concentration. The process was then carried out in a 3 L fed-batch fermentation system that included an initial stage of biomass growth. Banana juice was used as the carbon source and fructose pulses were added to maintain the test sugar concentrations of 30, 40, and 50 g/L. The control strain, Cupriavidus necator (ATCC 17699), produced 2.816 g/L of PHB, while productivity of the most promising isolate, C. necator (CR-12), was 0.495 g/L. Maximum biomass production was obtained using 5% banana juice and 2 g/L ammonium chloride. PHB production was not detected in fed-batch fermentations supplemented with 30 or 40 g/L of fructose, while the mean PHB production in fermentations with 50 g/L of fructose was 1.3 g/L.

Polyhydroxybutyrate production from ultrasound-aided alkaline pretreated finger millet straw using Bacillus megaterium strain CAM12

In this study, finger millet straw (FMS) was utilized for the production of Polyhydroxybutyrate (PHB) by Bacillus megaterium strain CAM12. Ultrasound-assisted alkaline (NaOH) pretreatment of FMS under optimized conditions followed by enzymatic saccharification resulted in the maximum delignification (72%), hydrolysis yield (84%), glucose yield (86%) and xylose yield (61%). The effects of different pH, temperature, incubation period, inoculum concentration, agitation speed and FMS enzymatic hydrolysates concentration were investigated to improve the PHB production. Under optimized conditions, strain CAM12 used the FMS hydrolysates as the sole carbon source for their growth and produced 8.31 g L^-1 of PHB. The extracted polymer on Fourier transform infrared (FTIR), X-ray diffraction (XRD) and Nuclear magnetic resonance (NMR) analyses were confirmed to be PHB. These results suggest the potential of combined ultrasound and alkaline pretreated FMS hydrolysates as a promising feedstock for PHB production.

Production of polyhydroxyalkanoates using dairy processing waste - A review

Bio-plastics are eco-friendly biopolymers finding tremendous application in the food and pharmaceutical industries. Bio-plastics have suitable physicochemical, mechanical properties, and do not cause any type of hazardous pollution upon disposal but have a high production cost. This can be minimized by screening potential bio-polymers producing strains, selecting inexpensive raw material, optimized cultivation conditions, and upstream processing. These bio-plastics specifically microbial-produced bio-polymers such as polyhydroxyalkanoates (PHAs) find application in food industries as packaging material owing to their desirable water barrier and gas permeability properties. The present review deals with the production, recovery, purification, characterization, and applications of PHAs. This is a comprehensive first review will also focus on different strategies adopted for efficient PHA production using dairy processing waste, its biosynthetic mechanism, metabolic engineering, kinetic aspects, and also biodegradability testing at the lab and pilot plant level. In addition to that, the authors will be emphasizing more on novel PHAs nanocomposites synthesis strategies and their commercial applicability.

Bioprocess for co-production of polyhydroxybutyrate and violacein using Himalayan bacterium Iodobacter sp. PCH194

The co-production of industrially relevant biopolymers/biomolecules from microbes is of biotechnological importance. Herein, a unique bacterium, Iodobacter sp. PCH 194 from the kettle lake at Sach Pass in western Indian Himalaya was identified. It co-produces biopolymer polyhydroxyalkanoates (PHA) and biomolecule (violacein pigment). Statistical optimization yielded dual products in the medium augmented with glucose (4.0% w/v) and tryptone (0.5% w/v) as carbon and nitrogen sources, respectively. The purified PHA was polyhydroxybutyrate (PHB), and pigment constitutes of violacein (50-60%) and deoxyviolacein (40-50%). A bench-scale bioprocess in 22.0 L fermentor with 20% dissolved O₂ supply produced PHB (11.0 ± 1.0 g/L, 58% of dry cell mass) and violacein pigment (1.5 ± 0.08 g/L). PHB obtained was used for the preparation of bioplastic film. Violacein pigment experimentally validated for anticancerous and antimicrobial activities. In summary, a commercially implied bioprocess developed for the co-production of PHB and violacein pigment using the Himalayan bacterium.

Fed-batch polyhydroxybutyrate production by Paraburkholderia sacchari from a ternary mixture of glucose, xylose and arabinose

Polyhydroxybutyrate (PHB) is a biodegradable bioplastic that is comparable with many petroleum-based plastics in terms of mechanical properties and is highly biocompatible. Lignocellulosic biomass conversion into PHB can increase profit and add sustainability. Glucose, xylose and arabinose are the main monomer sugars derived from upstream lignocellulosic biomass processing. The sugar mixture ratios may vary greatly depending on the pretreatment and enzymatic hydrolysis conditions. Paraburkholderia sacchari DSM 17165 is a bacterium strain that can convert all three sugars into PHB. In this study, fed-batch mode was applied to produce PHB on three sugar mixtures (glucose:xylose:arabinose = 4:2:1, 2:2:1, 1:2:1). The highest PHB concentration produced was 67 g/L for 4:2:1 mixture at 41 h corresponding to an accumulation of 77% of cell dry weight as PHB. Corresponding sugar conversion efficiency and productivity were 0.33 g PHB/g sugar consumed and 1.6 g/L/h, respectively. The results provide references for process control to maximize PHB production from real sugar streams derived from corn fibre.

Recent advances in polyhydroxyalkanoate production: Feedstocks, strains and process developments

Polyhydroxyalkanoates (PHAs) have been actively studied in academia and industry for their properties comparable to petroleum-derived plastics and high biocompatibility. However, the major limitation for commercialization is their high cost. Feedstock costs, especially carbon costs, account for the majority of the final cost. Finding cheap feedstocks for PHA production and associated process development are critical for a cost-effective PHA production. In this study, waste materials from different sources, particularly lignocellulosic biomass, were proposed as suitable feedstocks for PHA production. Strains involved in the conversion of these feedstocks into PHA were reviewed. Newly isolated strains were emphasized. Related process development, including the factors that affect PHA production, fermentation modes and downstream processing, was elaborated upon.

Response surface method for polyhydroxybutyrate (PHB) bioplastic accumulation in Bacillus drentensis BP17 using pineapple peel

Polyhydroxybutyrate (PHB) is a biodegradable biopolymer which is useful for various applications including packing, medical and coating materials. An endospore-forming bacterium (strain BP17) was isolated from composted soil and evaluated for PHB production. Strain BP17, taxonomically identified as Bacillus drentensis, showed enhanced PHB accumulation and was selected for further studies. To achieve maximum PHB production, the culture conditions for B. drentensis BP17 were optimized through response surface methodology (RSM) employing central composite rotatable design (CCRD). The final optimum fermentation conditions included: pineapple peel solution, 11.5% (v/v); tryptic soy broth (TSB), 60 g/L; pH, 6.0; inoculum size, 10% (v/v) and temperature, 28°C for 36 h. This optimization yielded 5.55 g/L of PHB compared to the non-optimized condition (0.17 g/L). PHB accumulated by B. drentensis BP17 had a polydispersity value of 1.59 and an average molecular weight of 1.15x105 Da. Thermal analyses revealed that PHB existed as a thermally stable semi-crystalline polymer, exhibiting a thermal degradation temperature of 228°C, a melting temperature of 172°C and an apparent melting enthalpy of fusion of 83.69 J/g. It is evident that B. drentensis strain BP17 is a promising bacterium candidate for PHB production using agricultural waste, such as pineapple peel as a low-cost alternative carbon source for PHB production.