Pilot-scale biopesticide production by Bacillus thuringiensis subsp. kurstaki using starch industry wastewater as raw material

On-farm Production of Microbial Entomopathogens for use in Agriculture: Brazil as a Case Study

In Brazil, the production of beneficial microorganisms by growers exclusively for their own use is a practice known as "on-farm production". Regarding on-farm bioinsecticides, they were initially deployed for pests of perennial and semi-perennial crops in the 1970s but, since 2013, their use has extended to pests of annual crops such as maize, cotton, and soybean. Millions of hectares are currently being treated with these on-farm preparations. Local production reduces costs, meets local needs, and reduces inputs of environmentally damaging chemical pesticides, facilitating establishment of more sustainable agroecosystems. Critics argue that without implementation of stringent quality control measures there is the risk that the on-farm preparations: (1) are contaminated with microbes which may include human pathogens or (2) contain very little active ingredient, impacting on field efficacy. The on-farm fermentation of bacterial insecticides predominates, especially that of Bacillus thuringiensis targeting lepidopteran pests. However, there has been a rapid growth in the past 5 years in the production of entomopathogenic fungi, mostly for the control of sap-sucking insects such as whitefly (Bemisia tabaci (Gennadius)) and the corn leafhopper (Dalbulus maidis (DeLong and Wolcott)). In contrast, on-farm production of insect viruses has seen limited growth. Most of the ca. 5 million rural producers in Brazil own small or medium size properties and, although the vast majority still do not practice on-farm production of biopesticides, the topic has aroused interest among them. Many growers who adopt this practice usually use non-sterile containers as fermenters, resulting in poor-quality preparations, and cases of failure have been reported. On the other hand, some informal reports suggest on-farm preparations may be efficacious even when contaminated, what could be explained, at least partially, by the insecticidal secondary metabolites secreted by the pool of microorganisms in the liquid culture media. Indeed, there is insufficient information on efficacy and mode of action of these microbial biopesticides. It is usually the large farms, some with > 20,000 ha of continuous cultivated lands, that produce biopesticides with low levels of contamination, as many of them possess advanced production facilities and have access to specialized knowledge and trained staff. Uptake of on-farm biopesticides is expected to continue but the rate of adoption will depend on factors such as the selection of safe, virulent microbial strains and implementation of sound quality control measures (compliance with emerging Brazilian regulations and international standards). The challenges and opportunities of on-farm bioinsecticides are presented and discussed.

Pilot-scale production and in-situ application of petroleum-degrading enzyme cocktail from Alcanivorax borkumensis

Petroleum degrading enzymes can be used as an alternative way to improve petroleum bioremediation approaches. Alcanivorax borkumensis is an alkane-degrading bacteria that can produce petroleum degrading enzymes such as alkane hydroxylase and lipase. In this study, pilot-scale Alcanivorax borkumensis fermentation was developed for producing large volumes of petroleum degrading enzymes cocktail (∼900 L). Different process conditions, such as inoculum age 72 h and size 4% v/v, temperature 30 ± 1 °C, agitation speed at 150 rpm and, fermentation period 3 days were determined as the optimum for producing alkane hydroxylase and lipase activity. The oxygen transfer capacity was studied for obtaining better bacterial growth and higher enzyme activities in bioreactor process optimization as well as scale-up. Results showed that the maximum values of oxygen mass transfer coefficient (k_La), oxygen uptake rate (OUR), oxygen transfer rate (OTR), alkane hydroxylase, lipase, and cell count were 196.95 h^-1, 0.92 mmol O₂/L/h, 1.8 mmol O₂/L/h, 222.49 U/mL, 325 U/mL, and 8.6 × 10¹⁰ CFU/mL, respectively. Compared with the bench-scale bioreactors, the 150 L fermenter showed a better oxygen transfer rate which affected the cell growth that doubled the number and enzymes production that increased. Then, the enzyme cocktail was used for a field test in a diesel source zone using a 5-spot well pattern. The results showed a significant reduction in concentrations of C10 - C50 (from 36% to > 99%) after one injection of enzyme cocktail, mainly for the contaminated soils located in the saturated zone of the unconfined aquifer. This study confirmed the scaling-up ofalkane-degrading enzyme production to an industrial-scale and its application for effective bioremediation of petroleum contaminated sites.

Insights on sustainable approaches for production and applications of value added products

The increasing demand for the development of sustainable strategies to utilize and process agro-industrial residues paves new paths for exploring innovative approaches in this area. Biotechnology based microbial transformations provide efficient, low cost and sustainable approaches for the production of value added products. The use of organic rich residues opens new avenues for the production of enzymes, pigments, biofuels, bioactive compounds, biopolymers etc. with vast industrial and therapeutic applications. Innovative technologies like strain improvement, enzyme immobilization, genome editing, morphological engineering, ultrasound/supercritical fluid/pulse electric field extraction, etc. can be employed. These will be helpful in achieving significant improvement in qualitative and quantitative parameters of the finished products. The global trend for the valorisation of biowaste has boosted the commercialization of these products which has transformed the markets by providing new investment opportunities. The upstream processing of raw materials using microbes poses a limitation in terms of product development and recovery which can be overcome by modifying the bioreactor design, physiological parameters or employing alternate technologies which will be discussed in this review. The other problems related to the processes include product stability, industrial applicability and cost competitiveness which needs to be addressed. This review comprehensively discusses the recent progress, avenues and challenges in the approaches aimed at valorisation of agro-industrial wastes along with possible opportunities in the bioeconomy.

Strategies for capturing Bacillus thuringiensis spores on surfaces of (001) GaAs-based biosensors

Bacillus thuringiensis (Bt) is used as a bioinsecticide since it effectively kills insect larvae. Bt is also genetically similar to Bacillus cereus (Bc), a well recognized foodborne human pathogen; they are both members of the Bacillus cereus group (BC group). Although approved Bt bioinsecticide products have been confirmed to be non-pathogenic to humans, close monitoring of Bt during dissemination is important for cost considerations and to limit impact on biodiversity towards nontarget organisms. As such, developing rapid, sensitive, and specific tools for quantitative detection of Bt spores during and following spray operations is highly desirable. The goals of this study were to investigate commercially available detection reagents for sensitivity and selectivity in detecting Bt spores, and then functionalize a surface of (001) GaAs used in photonic biosensing. To achieve these goals, we (1) screened commercial antibodies for their capacity to bind recombinant proteins from Bt spores, (2) screened antibodies and aptamers for their sensitivity and selectivity against Bt spores, and (3) tested the efficiency of selected antibodies and aptamers in capturing Bt spores on the surface of functionalized GaAs biochips. Seven genes encoding Bt spore proteins were cloned and expressed in Escherichia coli. The binding of each purified spore antigen was tested by commercially available polyclonal and monoclonal antibodies claimed to exclusively target spores. Of the seven targets, Bacillus collagen-like protein A, was the most abundant protein on Bt spores and demonstrated the strongest binding affinity to all test antibodies. The commercial antibodies (Abs) were also tested for specificity to BC Group versus non-BC Group spores. Three of six commercial antibodies showed selectivity to Bt spores, with recombinant Abs providing the most robust lower range of detection (10² to 6 × 10³ spores/mL). The sensitivity and selectivity of three published DNA aptamer sequences demonstrated a wide range of detection sensitivity for Bt spores. Two of the three test aptamers also showed reasonable selectivity towards Bt spores while the third demonstrated reactivity to non-BC Group B. megaterium and B. subtilis. Of the reagents tested, a thiolated aptamer and llama recombinant Ab showed highest Bt spore capture efficiency as measured by spore coverage of the GaAs surface. These results confirm that the selected aptamer and llama rAb can be considered strong candidates for the development of GaAs-based biosensing devices.

Bioprocesses for the recovery of bioenergy and value-added products from wastewater: A review

Wastewater and activated sludge present a major challenge worldwide. Wastewater generated from large and small-scale industries, laundries, human residential areas and other sources is emerging as a main problem in sanitation and maintenance of smart/green cities. During the last decade, different technologies and processes have been developed to recycle and purify the wastewater. Currently, identification and fundamental consideration of development of more advanced microbial-based technologies that enable wastewater treatment and simultaneous resource recovery to produce bioenergy, biofuels and other value-added compounds (organic acids, fatty acids, bioplastics, bio-pesticides, bio-surfactants and bio-flocculants etc.) became an emerging topic. In the last several decades, significant development of bioprocesses and techniques for the extraction and recovery of mentioned valuable molecules and compounds from wastewater, waste biomass or sludge has been made. This review presents different microbial-based process routes related to resource recovery and wastewater application for the production of value-added products and bioenergy. Current process limitations and insights for future research to promote more efficient and sustainable routes for this under-utilized and continually growing waste stream are also discussed.

Production of Bacillus thuringiensis based biopesticide formulation using starch industry wastewater (SIW) as substrate: A techno-economic evaluation

In this study, cost simulation was made to produce Bacillus thuriengiensis based biopesticide formulation using starch industry wastewater (SIW) as substrate. The results obtained at pilot plant (2000L capacity fermenter) were used for cost simulation of the process. The unit production cost for annual production of 5 million L of formulated biopesticide (20.2 Billion International Units (BIU)/L) was estimated to be $ 2.54/L, which is competitive to chemical pesticides. The techno-economic evaluation revealed that the profitability of the biopesticide manufacturing process was sensitive to the plant capacity and selling price of the biopesticide. The manufacturer should target 5 million L annual plant capacity and selling price of $ 15/L for payback period to be less than 5 years. The process serves many advantages (1) alternate disposal or bio-valorisation of industry wastewater and (2) use of industry wastewater as inexpensive carbon source reducing cost of raw materials for fermentation.

Biopesticide and formulation processes based on starch industrial wastewater fortified with soybean medium

The aim of this study was to produce Bacillus thuringiensis-based biopesticide using starch-producing industry wastewater (SIW) fortified with soybean medium and optimize the formulated product using different adjuvants. This study was necessary as low endotoxin concentration is obtained in formulated biopesticide when SIW alone is used as fermentation medium. The fermentation runs were conducted using SIW alone and SIW fortified with 25% soybean (w/v) medium in 2000 L and 150 L bioreactor, respectively. SIW supplemented with soybean medium showed an increase in cell count (from 1.95 × 108 to 1.65 × 109 CFU mL-1), spore synthesis (from 1.5 × 108 to 1.35 × 109 CFU mL-1) and endotoxin concentration (from 436 to 1170 μg mL-1) when compared to SIW medium alone. The fermented broth was concentrated using continuous centrifugation and adjuvants were added for biopesticide formulation in order to enhance its resistance against UV rays and rainfastness. Entomotoxicity of the formulation produced using fermented broth of SIW fortified with soybean (38,000 IU μL-1) was higher than that obtained by SIW medium alone (21,000 IU μL-1), commercial biopesticide Foray 76B (20,000 IU μL-1) and Btk sander's (12,500 IU μL-1).

Alternative low-cost process for large-scale production of Bacillus thuringiensis in a simple and novel culture system

An industrial-scale, profitable method for production of the most widely used bioinsecticide, Bacillus thuringiensis (Bt), is challenging because of its widespread application. The aim of this study is to present a strategy to develop a low-cost, large-scale bioprocess to produce Bt H14. This study was first focused on the design of a culture medium composed of economical and available components, such as glycerol and lysed Saccharomyces cerevisiae. The production goal of 1200 ITU was achieved using a medium composed of 20:20 g L^-1of glycerol:lysed yeast in batch cultures. Efforts were subsequently focused on the design of an appropriate culture system, and an original two-stage culture system was proposed. First, yeast (the primary component of the culture medium) are cultivated using a minimal mineral medium and lysed, and in the second stage, Bt is cultivated in the same bioreactor using the lysed yeasts as culture medium (supplemented with a feeding pulse of 10 g L^-1 glycerol). This system was called fed batch one pot (FOP). A new inoculation strategy is also presented in this study, since these Bt cultures were inoculated directly with heat pre-treated spores instead of vegetative bacteria to facilitate the bioprocess. This study was developed from the laboratory to production-scale bioreactors (measuring from 500 mL to 2500 L), and the efficiency of the proposed strategy was evident in LD₅₀ tests results, achieving 1796 ITU in large-scale processes. Both the use of non-conventional sources and the process development for biomass production are important for cost-effective production of Bt-based insecticides in mosquito control projects.