Continuous lactic acid production in whey permeate/yeast extract medium with immobilized Lactobacillus helveticus in a two-stage process: Model and experiments

Lactic acid production - producing microorganisms and substrates sources-state of art

Lactic acid is an organic compound produced via fermentation by different microorganisms that are able to use different carbohydrate sources. Lactic acid bacteria are the main bacteria used to produce lactic acid and among these, Lactobacillus spp. have been showing interesting fermentation capacities. The use of Bacillus spp. revealed good possibilities to reduce the fermentative costs. Interestingly, lactic acid high productivity was achieved by Corynebacterium glutamicum and E. coli, mainly after engineering genetic modification. Fungi, like Rhizopus spp. can metabolize different renewable carbon resources, with advantageously amylolytic properties to produce lactic acid. Additionally, yeasts can tolerate environmental restrictions (for example acidic conditions), being the wild-type low lactic acid producers that have been improved by genetic manipulation. Microalgae and cyanobacteria, as photosynthetic microorganisms can be an alternative lactic acid producer without carbohydrate feed costs. For lactic acid production, it is necessary to have substrates in the fermentation medium. Different carbohydrate sources can be used, from plant waste as molasses, starchy, lignocellulosic materials as agricultural and forestry residues. Dairy waste also can be used by the addition of supplementary components with a nitrogen source.

Immobilization of Lactobacillus rhamnosus in polyvinyl alcohol/calcium alginate matrix for production of lactic acid

Immobilization of Lactobacillus rhamnosus ATCC7469 in poly(vinyl alcohol)/calcium alginate (PVA/Ca-alginate) matrix using "freezing-thawing" technique for application in lactic acid (LA) fermentation was studied in this paper. PVA/Ca-alginate beads were made from sterile and non-sterile PVA and sodium alginate solutions. According to mechanical properties, the PVA/Ca-alginate beads expressed a strong elastic character. Obtained PVA/Ca-alginate beads were further applied in batch and repeated batch LA fermentations. Regarding cell viability, L. rhamnosus cells survived well rather sharp immobilization procedure and significant cell proliferation was observed in further fermentation studies achieving high cell viability (up to 10.7 log CFU g^-1) in sterile beads. In batch LA fermentation, the immobilized biocatalyst was superior to free cell fermentation system (by 37.1%), while the highest LA yield and volumetric productivity of 97.6% and 0.8 g L^-1 h^-1, respectively, were attained in repeated batch fermentation. During seven consecutive batch fermentations, the biocatalyst showed high mechanical and operational stability reaching an overall productivity of 0.78 g L^-1 h^-1. This study suggested that the "freezing-thawing" technique can be successfully used for immobilization of L. rhamnosus in PVA/Ca-alginate matrix without loss of either viability or LA fermentation capability.

Towards lactic acid bacteria-based biorefineries

Lactic acid bacteria (LAB) have long been used in industrial applications mainly as starters for food fermentation or as biocontrol agents or as probiotics. However, LAB possess several characteristics that render them among the most promising candidates for use in future biorefineries in converting plant-derived biomass-either from dedicated crops or from municipal/industrial solid wastes-into biofuels and high value-added products. Lactic acid, their main fermentation product, is an attractive building block extensively used by the chemical industry, owing to the potential for production of polylactides as biodegradable and biocompatible plastic alternative to polymers derived from petrochemicals. LA is but one of many high-value compounds which can be produced by LAB fermentation, which also include biofuels such as ethanol and butanol, biodegradable plastic polymers, exopolysaccharides, antimicrobial agents, health-promoting substances and nutraceuticals. Furthermore, several LAB strains have ascertained probiotic properties, and their biomass can be considered a high-value product. The present contribution aims to provide an extensive overview of the main industrial applications of LAB and future perspectives concerning their utilization in biorefineries. Strategies will be described in detail for developing LAB strains with broader substrate metabolic capacity for fermentation of cheaper biomass.

Cheese whey management: a review

Cheese whey is simultaneously an effluent with nutritional value and a strong organic and saline content. Cheese whey management has been focused in the development of biological treatments without valorization; biological treatments with valorization; physicochemical treatments and direct land application. In the first case, aerobic digestion is reported. In the second case, six main processes are described in the literature: anaerobic digestion, lactose hydrolysis, fermentation to ethanol, hydrogen or lactic acid and direct production of electricity through microbial fuel cells. Thermal and isoelectric precipitation, thermocalcic precipitation, coagulation/flocculation, acid precipitation, electrochemical and membrane technologies have been considered as possible and attractive physicochemical processes to valorize or treat cheese whey. The direct land application is a common and longstanding practice, although some precautions are required. In this review, these different solutions are analyzed. The paper describes the main reactors used, the influence of the main operating variables, the microorganisms or reagents employed and the characterizations of the final effluent principally in terms of chemical oxygen demand. In addition, the experimental conditions and the main results reported in the literature are compiled. Finally, the comparison between the different treatment alternatives and the presentation of potential treatment lines are postulated.

Biotechnological approaches for the value addition of whey

Whey, the liquid remaining after milk fat and casein have been separated from whole milk, is one of the major disposal problems of the dairy industry, and demands simple and economical solutions. In view of the fast developments in biotechnological techniques, alternatives of treating whey by transforming lactose present in it to value added products have been actively explored. Whey can be used directly as a substrate for the growth of different microorganisms to obtain various products such as ethanol, single-cell protein, enzymes, lactic acid, citric acid, biogas and so on. In this review, a comprehensive and illustrative survey is made to elaborate the various biotechnological innovations/techniques applied for the effective utilization of whey for the production of different bioproducts.

New trends and challenges in lactic acid production on renewable biomass

Lactic acid is a relatively cheap chemical with a wide range of applications: as a preservative and acidifying agent in food and dairy industry, a monomer for biodegradable poly-lactide polymers (PLA) in pharmaceutical industry, precursor and chemical feedstock for chemical, textile and leather industries. Traditional raw materials for fermentative production of lactic acid, refined sugars, are now being replaced with starch from corn, rice and other crops for industrial production, with a tendency for utilization of agro industrial wastes. Processes based on renewable waste sources have ecological (zero CO2 emission, eco-friendly by-products) and economical (cheap raw materials, reduction of storage costs) advantages. An intensive research interest has been recently devoted to develop and improve the lactic acid production on more complex industrial by-products, like thin stillage from bioethanol production, corncobs, paper waste, straw etc. Complex and variable chemical composition and purity of these raw materials and high nutritional requirements of Lare the main obstacles in these production processes. Media supplementation to improve the fermentation is an important factor, especially from an economic point of view. Today, a particular challenge is to increase the productivity of lactic acid production on complex renewable biomass. Several strategies are currently being explored for this purpose such as process integration, use of Lwith amylolytic activity, employment of mixed cultures of Land/or utilization of genetically engineered microorganisms. Modern techniques of genetic engineering enable construction of microorganisms with desired characteristics and implementation of single step processes without or with minimal pre-treatment. In addition, new bioreactor constructions (such as membrane bioreactors), utilization of immobilized systems are also being explored. Electrodialysis, bipolar membrane separation process, enhanced filtration techniques etc. can provide some progress in purification technologies, although it is still remaining the most expensive phase in the lactic acid production. A new approach of parallel production of lactic bacteria biomass with probiotic activity and lactic acid could provide additional benefit and profit rise in the production process.

Development of silk fibroin-based beads for immobilized cell fermentations

Silk fibroin was evaluated as a new matrix for immobilized cell fermentation. Silk fibroin was extracted from Bombyx mori cocoon, purified, concentrated in polyethylene glycol solution and diluted to 3 wt% with distilled water. This fibroin solution was used to encapsulate sensitive cells of the probiotic strain, Bifidobacterium longum ATCC 15707. Polymer droplets produced with an encapsulator were collected in liquid nitrogen and lyophilized. A low overall survival of 0.2% was measured after lyophilization. Lyophilized beads were hardened for 24 h under vacuum with an atmosphere of 89% relative humidity. The inoculated beads were colonized in two successive batch fermentations. Structure of silk fibroin beads and colonization of cells were examined with scanning electron microscopy. Colonized beads were tested in continuous fermentations for cell production. A biomass productivity of 1.7 x 10(9) CFU ml(-1) h(-1) was achieved, which was limited by loss of bead structure. This instability might be due to bead degradation by proteolytic activity of cells and/or limited mechanical stability during continuous fermentation in the stirred tank reactor.

Fermentation technologies for the production of probiotics with high viability and functionality

There is growing scientific evidence supported by mechanistic and clinical studies that probiotics can provide health benefits. As probiotics are highly sensitive to many environmental factors, and because the propagation of many strains of intestinal origin is not straightforward, most commercial strains are selected on the basis of their technological properties - ruling out some strains with promising health properties. To date, probiotic production has almost exclusively been carried out using conventional batch fermentation and suspended cultures, in some cases combined with the use of sublethal stresses to enhance cell viability, the addition of protectants or microencapsulation to provide cell protection. However, other less conventional fermentation technologies, such as continuous culture and immobilized cell systems, could have potential for enhancing the performance of these fastidious organisms. These technologies might be employed to develop strains with improved physiology and functionality in the gut and to enlarge the range of commercially available probiotics, as well as expanding product applications.

Optimization of lactic acid production by immobilized Lactococcus lactis IO-1

Production of lactic acid from glucose by immobilized cells of Lactococcus lactis IO-1 was investigated using cells that had been immobilized by either entrapment in beads of alginate or encapsulation in microcapsules of alginate membrane. The fermentation process was optimized in shake flasks using the Taguchi method and then further assessed in a production bioreactor. The bioreactor consisted of a packed bed of immobilized cells and its operation involved recycling of the broth through the bed. Both batch and continuous modes of operation of the reactor were investigated. Microencapsulation proved to be the better method of immobilization. For microencapsulated cells at immobilized cell concentration of 5.3 g l(-1), the optimal production medium had the following initial concentrations of nutrients (g l(-1)): glucose 45, yeast extract 10, beef extract 10, peptone 7.5 and calcium chloride 10 at an initial pH of 6.85. Under these conditions, at 37 degrees C, the volumetric productivity of lactic acid in shake flasks was 1.8 g l(-1) h(-1). Use of a packed bed of encapsulated cells with recycle of the broth through the bed, increased the volumetric productivity to 4.5 g l(-1) h(-1). The packed bed could be used in repeated batch runs to produce lactic acid.