Control of the specific growth rate of Bacillus subtilis for the production of biosurfactant lipopeptides in bioreactors with foam overflow

Unveiling the potential of specific growth rate control in fed-batch fermentation: bridging the gap between product quantity and quality

During the epoch of sustainable development, leveraging cellular systems for production of diverse chemicals via fermentation has garnered attention. Industrial fermentation, extending beyond strain efficiency and optimal conditions, necessitates a profound understanding of microorganism growth characteristics. Specific growth rate (SGR) is designated as a key variable due to its influence on cellular physiology, product synthesis rates and end-product quality. Despite its significance, the lack of real-time measurements and robust control systems hampers SGR control strategy implementation. The narrative in this contribution delves into the challenges associated with the SGR control and presents perspectives on various control strategies, integration of soft-sensors for real-time measurement and control of SGR. The discussion highlights practical and simple SGR control schemes, suggesting their seamless integration into industrial fermenters. Recommendations provided aim to propose new algorithms accommodating mechanistic and data-driven modelling for enhanced progress in industrial fermentation in the context of sustainable bioprocessing.

Adaptive control of the E. coli-specific growth rate in fed-batch cultivation based on oxygen uptake rate

In this study, an automatic control system is developed for the setpoint control of the cell biomass specific growth rate (SGR) in fed-batch cultivation processes. The feedback signal in the control system is obtained from the oxygen uptake rate (OUR) measurement-based SGR estimator. The OUR online measurements adapt the system controller to time-varying operating conditions. The developed approach of the PI controller adaptation is presented and discussed. The feasibility of the control system for tracking a desired biomass growth time profile is demonstrated with numerical simulations and fed-batch culture E . c o l i control experiments in a laboratory-scale bioreactor. The procedure was cross-validated with the open-loop digital twin SGR estimator, as well as with the adaptive control of the SGR, by tracking a desired setpoint time profile. The digital twin behavior statistically showed less of a bias when compared to SGR estimator performance. However, the adaptation-when using first principles-was outperformed 30 times by the model predictive controller in a robustness check scenario.

Enhanced biosurfactant production by Bacillus subtilis SPB1 using developed fed-batch fermentation: effects of glucose levels and feeding systems

Biosurfactants stand for highly useful and promising compounds. They basically serve for a variety of applications in multiple industries and aspects of human life. Therefore, it is highly required to improve their production yield especially through the development of new and more efficient fermentation processes. In this aim, batch and fed-batch were studied and compared in terms of their effective biosurfactant production by Bacillus subtilis SPB1. Experiments of fed-batch fermentations were carried out through three different glucose feeding strategies, namely the pulsed, the constant Donespeed and the exponential feeding. The comparison between different fermentation processes revealed that fed-batch process proved to be a more efficient cultivation strategy than the batch process in terms of cell biomass, biosurfactant production and productivity. Among the three different feeding strategies, the exponential feeding process achieved the highest fermentation results of final biosurfactant concentration. The latter increased more than twofolds compared to batch fermentation.

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.

Bacillus subtilis strain BS06 protects soybean roots from Fusarium oxysporum infection

Soybean, as a major oil crop, is one of the most widely planted crops in the world. Fusarium oxysporum causes soybean root rot, leading to great economic losses to soybean planting every year globally. Chemical fungicide for controlling soybean F. oxysporum diseases may cause environmental problems and has human health risks. Biological control methods avoid these shortcomings; however, few studies have focused on biocontrol of soybean diseases caused by F. oxysporum. Aiming at this problem, we obtained biocontrol bacteria against soybean F. oxysporum by plate confrontation method. The type of the strain with the highest biocontrol activity was identified by molecular biological methods, and then its biocontrol effects were verified through greenhouse experiments. One of our isolated strain named BS06 strain had the highest activity, which was identified as Bacillus subtilis. Our study showed that BS06 strain could effectively control soybean F. oxysporum disease and significantly reduce F. oxysporum to infect soybean roots. Compared with control and carbendazim treatments, BS06 treatment had higher root biomass, plant height, leaf chlorophyll content, stem base diameter and control efficiency. Our results indicated that BS06 could effectively protect soybean root (BS06 strain might produce substances to inhibit F. oxysporum), which was potentially useful for soybean planting.

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.

Bacillus subtilis High Cell Density Fermentation Using a Sporulation-Deficient Strain for the Production of Surfactin

Abstract

Bacillus subtilis 3NA is a strain capable of reaching high cell densities. A surfactin producing sfp⁺ variant of this strain, named JABs32, was utilized in fed-batch cultivation processes. Both a glucose and an ammonia solution were fed to set a steady growth rate μ of 0.1 h^-1. In this process, a cell dry weight of up to 88 g L^-1 was reached after 38 h of cultivation, and surfactin titers of up to 26.5 g L^-1 were detected in this high cell density fermentation process, achieving a Y_P/X value of 0.23 g g^-1 as well as a q_P/X of 0.007 g g^-1 h^-1. In sum, a 21-fold increase in surfactin titer was obtained compared with cultivations in shake flasks. In contrast to fed-batch operations using Bacillus subtilis JABs24, an sfp⁺ variant derived from B. subtilis 168, JABs32, reached an up to fourfold increase in surfactin titers using the same fed-batch protocol. Additionally, a two-stage feed process was established utilizing strain JABs32. Using an optimized mineral salt medium in this high cell density fermentation approach, after 31 h of cultivation, surfactin titers of 23.7 g L^-1 were reached with a biomass concentration of 41.3 g L^-1, thus achieving an enhanced Y_P/X value of 0.57 g g^-1 as well as a q_P/X of 0.018 g g^-1 h^-1. The mutation of spo0A locus and an elongation of AbrB in the strain utilized in combination with a high cell density fed-batch process represents a promising new route for future enhancements on surfactin production.

Key points

• Utilization of a sporulation deficient strain for fed-batch operations

• High cell density process with Bacillus subtilis for lipopeptide production was established

• High titer surfactin production capabilities confirm highly promising future platform strain

Practical Solutions for Specific Growth Rate Control Systems in Industrial Bioreactors

This contribution discusses the main challenges related to successful application of automatic control systems used to control specific growth rate in industrial biotechnological processes. It is emphasized that, after the implementation of basic automatic control systems, primary attention shall be paid to the specific growth rate control systems because this process variable critically affects the physiological state of microbial cultures and the formation of the desired product. Therefore, control of the specific growth rate enables improvement of the quality and reproducibility of the biotechnological processes. The main requirements have been formulated that shall be met to successfully implement the specific growth rate control systems in industrial bioreactors. The relatively easy-to-implement schemes of specific growth rate control systems have been reviewed and discussed. The recommendations for selection of particular control systems for specific biotechnological processes have been provided.

High-throughput optimization of medium components and culture conditions for the efficient production of a lipopeptide pseudofactin by Pseudomonas fluorescens BD5

Background

Lipopeptides are a promising group of surface-active compounds of microbial origin (biosurfactants). These diverse molecules are produced mainly by Bacillus and Pseudomonas strains. Because of their attractive physiochemical and biological properties, biosurfactants are considered to be “green and versatile molecules of the future”. The main obstacles in widespread use of biosurfactants are mainly their low yields and high production costs. Pseudofactin (PF) is a lipopeptide produced by Pseudomonas fluorescens BD5. Recently, we identified two analogues, PF1 (C₁₆-Val) and PF2 (C₁₆-Leu), and reported that PF2 has good emulsification and foaming activities, as well as antibacterial, antifungal, anticancer, and antiadhesive properties. Reported production of PF in a mineral salt medium was approximately 10 mg/L.

Results

Here, we report successful high-throughput optimization of culture medium and conditions for efficient PF production using P. fluorescens BD5. Compared with production in minimal medium, PF yield increased almost 120-fold, up to 1187 ± 13.0 mg/L. Using Plackett–Burman and central composite design methodologies we identified critical factors that are important for efficient PF production, mainly high glycerol concentration, supplementation with amino acids (leucine or valine) and complex additives (e.g. tryptone), as well as high culture aeration. We also detected the shift in a ratio of produced PF analogues in response to supplementation with different amino acids. Leucine strongly induces PF2 production, while valine addition supports PF1 production. We also reported the identification of two new PF analogues: PF3 (C₁₈-Val) and PF4 (C₁₈-Leu).

Conclusions

Identification of critical culture parameters that are important for lipopeptide production and their high yields can result in reduction of the production costs of these molecules. This may lead to the industrial-scale production of biosurfactants and their widespread use. Moreover, we produced new lipopeptide pure analogues that can be used to investigate the relationship between the structure and biological activity of lipopeptides.

Electronic supplementary material

The online version of this article (10.1186/s12934-018-0968-x) contains supplementary material, which is available to authorized users.

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.

Control of agitation and aeration rates in the production of surfactin in foam overflowing fed-batch culture with industrial fermentation

Bacillus amyloliquefaciens fmb50 produces a high yield of surfactin, a lipopeptide-type biosurfactant that has been widely studied and has potential applications in many fields. A foam overflowing culture has been successfully used in the combined production-enrichment fermentation of surfactin. In this study, the agitation and aeration rates were found to have relationships with foam formation and surfactin enrichment. A maximum surfactin concentration of 4.7g/l of foam was obtained after 21h of culture with an agitation rate of 150rpm and an aeration rate of 1vvm in fed-batch culture. By controlling the foam overflow rate (fout) of a fed-batch culture, surfactin concentration in the foam was continuously maintained above 4g/l.

Mycosubtilin and surfactin are efficient, low ecotoxicity molecules for the biocontrol of lettuce downy mildew

The use of surfactin and mycosubtilin as an eco-friendly alternative to control lettuce downy mildew caused by the obligate pathogen Bremia lactucae was investigated. Preliminary ecotoxicity evaluations obtained from three different tests revealed the rather low toxicity of these lipopeptides separately or in combination. The EC50 (concentration estimated to cause a 50 % response by the exposed test organisms) was about 100 mg L(-1) in Microtox assays and 6 mg L(-1) in Daphnia magna immobilization tests for mycosubtilin and 125 mg L(-1) and 25 mg L(-1) for surfactin, respectively. The toxicity of the mixture mycosubtilin/surfactin (1:1, w/w) was close to that obtained with mycosubtilin alone. In addition, the very low phytotoxic effect of these lipopeptides has been observed on germination and root growth of garden cress Lepidium sativum L. While a surfactin treatment did not influence the development of B. lactucae on lettuce plantlets, treatment with 100 mg L(-1) of mycosubtilin produced about seven times more healthy plantlets than the control samples, indicating that mycosubtilin strongly reduced the development of B. lactucae. The mixture mycosubtilin/surfactin (50:50 mg L(-1)) gave the same result on B. lactucae development as 100 mg L(-1) of mycosubtilin. The results of ecotoxicity as well as those obtained in biocontrol experiments indicated that the presence of surfactin enhances the biological activities of mycosubtilin. Mycosubtilin and surfactin were thus found to be efficient compounds against lettuce downy mildew, with low toxicity compared to the toxicity values of chemical pesticides. This is the first time that Bacillus lipopeptides have been tested in vivo against an obligate pathogen and that ecotoxic values have been given for surfactin and mycosubtilin.

Purification and structural characterization of fengycin homologues produced by Bacillus subtilis LSFM-05 grown on raw glycerol

Raw glycerol is a byproduct of biodiesel production that currently has low to negative value for biodiesel producers. One option for increasing the value of raw glycerol is to use it as a feedstock for microbial production. Bacillus subtilis LSFM 05 was used for the production of fengycin in a mineral medium containing raw glycerol as the sole carbon source. Fengycin was isolated by acid precipitation at pH 2 and purified by silica gel column chromatography and characterized using electrospray ionization (ESI) Fourier transform ion cyclotron resonance mass spectrometry (ESI FT-ICR MS) with collision-induced dissociation (CID). The mass spectrum revealed the presence of the ions of m/z 1,435.7, 1,449.9, 1,463.8, 1,477.8, 1,491.8 and 1,505.8, which were further fragmented by ESI-MS/MS. The CID profile showed the presence of a series of ions (m/z 1,080 and 966) and (m/z 1,108 and 994) that represented the different fengycin homologues A and B, respectively. Fengycin homologues A and B are variants that differ at position 6 of the peptide moiety, having either Ala or Val residues, respectively. Mass spectrometry analyses identified four fengycin A and three fengycin B variants with fatty acid components containing 14-17 carbons. These results demonstrate that raw glycerol can be used as feedstock to produce fengycin, and additional work should focus on the optimization of process conditions to increase productivity.