Production of polyhydroxyalkanoates from waste frying oil by Cupriavidus necator

Perceiving biobased plastics as an alternative and innovative solution to combat plastic pollution for a circular economy

Plastic waste from fossil-based sources, including single-use packaging materials, is continuously accumulating in landfills, and leaching into the environment. A 2021 UN Environment Programme (UNEP) report suggests that the plastic pollution is likely to be doubled by 2030, posing a major challenge to the environment and the overall global plastic waste management efforts. The use of biobased plastics such as polyhydroxyalkanoates (PHAs) as a biodegradable substitute for petroleum-based plastics could be a feasible option to combat this issue which may further result in much lower carbon emissions and energy usage in comparison to conventional plastics as additional advantages. Though recent years have seen the use of microbes as biosynthetic machinery for biobased plastics, using various renewable feedstocks, the scaled-up production of such materials is still challenging. The current study outlays applications of biobased plastics, potential microorganisms producing biobased plastics such as Cupriavidus necator, Bacillus sp., Rhodopseudomonas palustris, microalgae, and mixed microbial cultures, and inexpensive and renewable resources as carbon substrates including industrial wastes. This review also provides deep insights into the operational parameters, challenges and mitigation, and future opportunities for maximizing the production of biobased plastic products. Finally, this review emphasizes the concept of biorefinery as a sustainable and innovative solution for biobased plastic production for achieving a circular bioeconomy.

Production of polyhydroxyalkanoates from renewable resources: a review on prospects, challenges and applications

Bioplastics replace synthetic plastics of petrochemical origin, which contributes challenge to both polymer quality and economics. Novel polyhydroxyalkanoates (PHA)-composite materials, with desirable product quality, could be developed, thus targeting the global plastics market, in the coming years. It is possible that PHA can be a greener substitute for their petroleum-based competitors since they are simply decomposed, which may lessen the pressure on municipal and industrial waste management systems. PHA production has proven to be the bottleneck in industrial application and commercialization because of the high price of carbon substrates and downstream processes required to achieve reliability. Bacterial PHA production by these municipal and industrial wastes, which act as a cheap, renewable carbon substrate, eliminates waste management hassles and acts as an efficient substitute for synthetic plastics. In the present review, challenges and opportunities related to the commercialization of polyhydroxyalkanoates are discussed and presented. Moreover, it discusses critical steps of their production process, feedstock evaluation, optimization strategies, and downstream processes. This information may provide us the complete utilization of bacterial PHA during possible applications in packaging, nutrition, medicine, and pharmaceuticals.

Polyhydroxybutyrate production from crude glycerol using a highly robust bacterial strain Halomonas sp. YLGW01

Petrochemical-based plastics are hardly biodegradable and a major cause of environmental pollution, and polyhydroxybutyrate (PHB) is attracting attention as an alternative due to its similar properties. However, the cost of PHB production is high and is considered the greatest challenge for its industrialization. Here, crude glycerol was used as a carbon source for more efficient PHB production. Among the 18 strains investigated, Halomonas taeanenisis YLGW01 was selected for PHB production due to its salt tolerance and high glycerol consumption rate. Furthermore, this strain can produce poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (P(3HB-co-3 HV)) with 17 % 3 HV mol fraction when a precursor is added. PHB production was maximized through medium optimization and activated carbon treatment of crude glycerol, resulting in 10.5 g/L of PHB with 60 % PHB content in fed-batch fermentation. Physical properties of the produced PHB were analyzed, i.e., weight average molecular weight (6.8 × 10⁵), number average molecular weight (4.4 × 10⁵), and the polydispersity index (1.53). In the universal testing machine analysis, the extracted intracellular PHB showed a decrease in Young's modulus, an increase in Elongation at break, greater flexibility than authentic film, and decreased brittleness. This study confirmed that YLGW01 is a promising strain for industrial PHB production using crude glycerol.

Trends and challenges in the valorization of kitchen waste to polyhydroxyalkanoates

Kitchen waste (KW) is frequently available for free or with a negative cost due to its huge production. It contains a large proportion of organic substances, especially fermentable sugars, which can be used for bioplastic (polyhydroxyalkanoates or PHA) synthesis. Nevertheless, due to the difficulties in processing, various pre-treatments of KW are being investigated to enhance the concentration of simple sugars released during its hydrolysis. The effective use of KW will help in minimizing the issues of its inappropriate disposal. However, the review on KW to bioplastic synthesis is rarely reported in the literature. Hence, this particular review provides a comprehensive summary of the updated research developments in KW valorization and its potency as a feedstock for PHAs synthesis. Additionally, the impacts of KW, its availability, the necessary pre-treatments for the biopolymerization process, as well as the prospects and challenges for industrially generating sustainable PHAs, are critically discussed.

Biosynthesis of poly(3-hydroxybutyrate-co-3-hydroxvalerate) from volatile fatty acids by Cupriavidus necator

A promising strategy to alleviate the plastic pollution from traditional petroleum-based plastics is the application of biodegradable plastics, in which polyhydroxyalkanoates (PHAs) have received increasing interest owing to their considerable biodegradability. In the PHAs family, poly(3-hydroxybutyrate-co-3-hydroxvalerate) (PHBV) has better mechanical properties, which possesses broader application prospects. With this purpose, the present study adopted Cupriavidus necator to synthesize PHBV utilizing volatile fatty acids (VFAs) as sole carbon sources. Results showed that the concentration and composition of VFAs significantly influenced the production of PHAs. Especially, even carbon VFAs (acetate and butyrate) synthesized only poly(3-hydroxybutyrate) (PHB), while the addition of odd carbon VFAs (propionate and valerate) resulted in PHBV production. The 3-hydroxyvalerate (3HV) contents in PHBV were directly determined by the specific VFAs compositions, in which valerate was the preferred substrate for 3HV accumulation. After optimization by response surface methodology, the highest PHBV accumulation achieved 79.47% in dry cells, and the conversion efficiency of VFAs to PHBV reached 40%, with the PHBV production of 1.20 ± 0.05 g/L. This study revealed the metabolic rule of VFAs converting into PHAs by C. necator and figured out the optimal VFAs condition for PHBV accumulation, which provides a valuable reference for developing downstream strategies of PHBV production in industrial applications in future.

A Novel Sphingomonas sp. Isolated from Argan Soil for the Polyhydroxybutyrate Production from Argan Seeds Waste

Polyhydroxybutyrate (PHB) is a biodegradable bio-based polymer synthesized by microorganisms under unfavorable conditions from agro-industrial residues as a source of carbon. These aspects make the bio-based polymer attractive for the mass production of biodegradable plastics, and a definitive replacement for petroleum-based plastics. The aim of this work was to characterize the putative PHB-producing bacterium 1B isolated from the argan soil, to identify the polymer produced, and quantify the PHB production using argan seeds waste. DNA extraction, PCR, and Sanger sequencing were conducted for the molecular identification of strain 1B; the residual biomass and the PHB quantification were measured and compared in the presence of simple sugars and pretreated argan seeds waste. The 1B growth and PHB synthesis were optimized by selecting physical and nutritional parameters: temperature, incubation time, pH, NaCl concentration, and nitrogen sources concentrations. A preliminary characterization of the bio-based polymer extracted was conducted by UV-Visible spectrophotometry and FTIR analysis. The strain 1B was identified as belonging to the genus Sphingomonas. The PHB final yield was higher in a growth culture enriched with argan waste (3.06%) than with simple sugars. The selected conditions for the bacterial optimal growth incremented the PHB final yield to 6.13%, while the increase in the argan residue concentration from 1 to 3% in a larger culture volume led to the PHB final yield of 8.16%. UV-Visible spectrophotometry of the extracted sample reported a remarkable peak at 248 nm, as well as FTIR spectra analysis, showed peaks at 1728 and 1282 wavenumber/cm. Both preliminary characterizations demonstrated that the extracted sample is the bio-based polymer polyhydroxybutyrate. The results reported in this work reveal how the costless available argan seeds can be used for polyhydroxybutyrate production using a novel Sphingomonas species.

Cupriavidus necator-Produced Polyhydroxybutyrate/Eudragit FS Hybrid Nanoparticles Mitigates Ulcerative Colitis via Colon-Targeted Delivery of Cyclosporine A

Polyhydroxybutyrate (PHB) has emerged as a novel material for replacing various plastics used in the medical field. However, its application as a drug-delivery carrier for colitis-targeted delivery has not been explored. In this study, we used biosynthesized PHB combined with Eudragit FS (EFS) and cyclosporine A (CSA) to develop pH-responsive controlled CSA-releasing nanoparticles (CSA-PENPs) for colitis-targeted drug delivery and demonstrated its enhanced therapeutic efficacy in a dextran sulfate sodium (DSS)-induced murine colitis model. PHB was successfully biosynthesized in the bacterium Cupriavidus necator, as demonstrated by ¹H-NMR and FT-IR analyses. CSA-PENPs were fabricated via the oil-in-water emulsion solvent evaporation method. Owing to the potent pH-responsive and sustained drug release properties provided by PHB and EFS, CSA-PENPs could deliver a sufficient amount of CSA to inflamed tissues in the distal colon; in contrast, CSA-loaded EFS nanoparticles displayed premature burst release before reaching the target site. Due to enhanced CSA delivery to colitis tissues, CSA-PENPs exhibited potent anti-inflammatory effects in the DSS-induced murine colitis model. Overall, CSA-PENPs could be a promising drug-delivery system for treating ulcerative colitis.

Fermentative α-Humulene Production from Homogenized Grass Clippings as a Growth Medium

Green waste, e.g., grass clippings, is currently insufficiently recycled and has untapped potential as a valuable resource. Our aim was to use juice from grass clippings as a growth medium for microorganisms. Herein, we demonstrate the production of the sesquiterpene α-humulene with the versatile organism Cupriavidus necator pKR-hum on a growth medium from grass clippings. The medium was compared with established media in terms of microbial growth and terpene production. C. necator pKR-hum shows a maximum growth rate of 0.43 h^-1 in the grass medium and 0.50 h^-1 in a lysogeny broth (LB) medium. With the grass medium, 2 mg/L of α-humulene were produced compared to 10 mg/L with the LB medium. By concentrating the grass medium and using a controlled bioreactor in combination with an optimized in situ product removal, comparable product concentrations could likely be achieved. To the best of our knowledge, this is the first time that juice from grass clippings has been used as a growth medium without any further additives for microbial product synthesis. This use of green waste as a material represents a new bioeconomic utilization option of waste materials and could contribute to improving the economics of grass biorefineries.

Evaluation of different nutrient limitation strategies for the efficient production of poly(hydroxybutyrate-co-hydroxyvalerate) from waste frying oil and propionic acid in high cell density fermentations of Cupriavidus necator H16

Because of its application potential and biodegradability, poly(3-hydroxybutyrate-co-3-hydroxyvalerate;PHBV), a member of the polyhydroxyalkanoates (PHA) biopolymer family, is one of the most extensively studied PHA. High PHBV productivity with a significant amount of hydroxyvalerate (HV) content is very appealing for commercial scale production. The goal of this study was to investigate the efficiency of various defined limitation strategies, namely nitrogen, phosphorus, and oxygen-limitation, for high yield PHBV production by Cupriavidus necator H16 with increased HV unit using waste frying vegetable oil (WFO) and propionic acid (PA) in a high cell density culture (5 L bioreactor). With optimized WFO and PA feeding, highest PHBV harvest (121.7 ± 2.59 g/L; HV 13.9 ± 0.44% (w/w)) and volumetric productivity (2.03 ± 0.04 gPHBV/L·h) were obtained in oxygen-limited operation, while highest HV content (19.8 ± 0.28 wt%) and yield coefficient (0.43 ± 0.017 gHV/gPA) were observed during phosphorus-limited cultivation. Although nitrogen limitation is widely applied in the production of PHA, nitrogen-limited cultivation had the lowest cell dry matter, PHBV production, volumetric productivity, oil-to-HB and PA-to-HV yield coefficients for the given conditions. The results of the present study demonstrate the highest PHBV yield together with the highest HV content using WFO as main carbon source and PA as the HV precursor ever reported in the literature.

A Review on Enhancing Cupriavidus necator Fermentation for Poly(3-hydroxybutyrate) (PHB) Production From Low-Cost Carbon Sources

In the context of a circular economy, bioplastic production using biodegradable materials such as poly(3-hydroxybutyrate) (PHB) has been proposed as a promising solution to fundamentally solve the disposal issue of plastic waste. PHB production techniques through fermentation of PHB-accumulating microbes such as Cupriavidus necator have been revolutionized over the past several years with the development of new strategies such as metabolic engineering. This review comprehensively summarizes the latest PHB production technologies via Cupriavidus necator fermentation. The mechanism of the biosynthesis pathway for PHB production was first assessed. PHB production efficiencies of common carbon sources, including food waste, lignocellulosic materials, glycerol, and carbon dioxide, were then summarized and critically analyzed. The key findings in enhancing strategies for PHB production in recent years, including pre-treatment methods, nutrient limitations, feeding optimization strategies, and metabolism engineering strategies, were summarized. Furthermore, technical challenges and future prospects of strategies for enhanced production efficiencies of PHB were also highlighted. Based on the overview of the current enhancing technologies, more pilot-scale and larger-scale tests are essential for future implementation of enhancing strategies in full-scale biogas plants. Critical analyses of various enhancing strategies would facilitate the establishment of more sustainable microbial fermentation systems for better waste management and greater efficiency of PHB production.

Functional bioplastics from food residual: Potentiality and safety issues

Plastic pollution and food waste are two global issues with much in common. Plastic containers were introduced as a practical and easy remedy to improve food preservation and reduce the risk of creating waste, but ironically, to address one problem, another has been made worse. The spread of single-use containers has dramatically increased the amount of plastic that has to be discarded, and the most urgent task is now to find a solution to what has become part of the problem. An innovative way around it consists of promoting the valorization of food residues by turning them into novel materials for packaging. Although the results are promising, the aim of completely replacing plastics with biodegradable materials still seems far from being achieved. This review illustrates the main strategies adopted thus far to produce new bioplastic materials and composites from waste resources and focuses on the pros and cons of the food recovery process to look for the aspects that represent an obstacle to the development of the circular food economy on an industrial scale.

Biomedical Applications of Polyhydroxyalkanoate in Tissue Engineering

Tissue engineering technology aids in the regeneration of new tissue to replace damaged or wounded tissue. Three-dimensional biodegradable and porous scaffolds are often utilized in this area to mimic the structure and function of the extracellular matrix. Scaffold material and design are significant areas of biomaterial research and the most favorable material for seeding of in vitro and in vivo cells. Polyhydroxyalkanoates (PHAs) are biopolyesters (thermoplastic) that are appropriate for this application due to their biodegradability, thermo-processability, enhanced biocompatibility, mechanical properties, non-toxicity, and environmental origin. Additionally, they offer enormous potential for modification through biological, chemical and physical alteration, including blending with various other materials. PHAs are produced by bacterial fermentation under nutrient-limiting circumstances and have been reported to offer new perspectives for devices in biological applications. The present review discusses PHAs in the applications of conventional medical devices, especially for soft tissue (sutures, wound dressings, cardiac patches and blood vessels) and hard tissue (bone and cartilage scaffolds) regeneration applications. The paper also addresses a recent advance highlighting the usage of PHAs in implantable devices, such as heart valves, stents, nerve guidance conduits and nanoparticles, including drug delivery. This review summarizes the in vivo and in vitro biodegradability of PHAs and conducts an overview of current scientific research and achievements in the development of PHAs in the biomedical sector. In the future, PHAs may replace synthetic plastics as the material of choice for medical researchers and practitioners.

A genome-scale metabolic model of Cupriavidus necator H16 integrated with TraDIS and transcriptomic data reveals metabolic insights for biotechnological applications

Exploiting biological processes to recycle renewable carbon into high value platform chemicals provides a sustainable and greener alternative to current reliance on petrochemicals. In this regard Cupriavidus necator H16 represents a particularly promising microbial chassis due to its ability to grow on a wide range of low-cost feedstocks, including the waste gas carbon dioxide, whilst also naturally producing large quantities of polyhydroxybutyrate (PHB) during nutrient-limited conditions. Understanding the complex metabolic behaviour of this bacterium is a prerequisite for the design of successful engineering strategies for optimising product yields. We present a genome-scale metabolic model (GSM) of C. necator H16 (denoted iCN1361), which is directly constructed from the BioCyc database to improve the readability and reusability of the model. After the initial automated construction, we have performed extensive curation and both theoretical and experimental validation. By carrying out a genome-wide essentiality screening using a Transposon-directed Insertion site Sequencing (TraDIS) approach, we showed that the model could predict gene knockout phenotypes with a high level of accuracy. Importantly, we indicate how experimental and computational predictions can be used to improve model structure and, thus, model accuracy as well as to evaluate potential false positives identified in the experiments. Finally, by integrating transcriptomics data with iCN1361 we create a condition-specific model, which, importantly, better reflects PHB production in C. necator H16. Observed changes in the omics data and in-silico-estimated alterations in fluxes were then used to predict the regulatory control of key cellular processes. The results presented demonstrate that iCN1361 is a valuable tool for unravelling the system-level metabolic behaviour of C. necator H16 and can provide useful insights for designing metabolic engineering strategies.

Genome-scale metabolic models (GSMs) provide a tool for unravelling the complex metabolic behaviour of bacteria and how they adapt to changing environments and genetic perturbations, and thus offer invaluable insights for biotechnology applications. For a GSM to be used efficiently for strain development purposes, however, the model must be easily readable and reusable by other researchers, whilst being able to predict metabolic behaviour with a high level of accuracy. In this work, we developed a GSM for Cupriavidus necator H16 that is linked to the BioCyc database, which provides an efficient way of application, model update, integration of experimental data and network visualisation for other researchers. Using our model, we demonstrate how integrating experimental observations, including Transposon-directed Insertion site Sequencing (TraDIS) and omics data, can be used to compensate for the lack of regulatory, kinetic and thermodynamic information in GSMs, and thus improve model accuracy. Importantly, we found that TraDIS in vivo screening and GSM analysis are complementary approaches, which can be used in combination to provide reliable gene essentiality predictions. Overall, our results offer an informed strategy for the deliberate manipulation of C. necator H16 metabolic capabilities, towards its industrial application to convert greenhouse gases into biochemicals and biofuels.

A fermentation process for the production of poly(3-hydroxybutyrate) using waste cooking oil or waste fish oil as inexpensive carbon substrate

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Both WCO and WFO can be used as promising substrates for PHA production.

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First report of a fed-batch fermentation process using WFO as sole carbon source for PHA production.

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High PHB yields of 0.8 g/g and 0.92 g/g were produced from WCO and WFO, respectively.

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Highest PHB productivity (1.73 g/L/h) was achieved when using waste oil as carbon source.

The utilization of waste cooking oil (WCO) or waste fish oil (WFO) as inexpensive carbon substrate for the production of poly(3-hydroxybutyrate) (PHB) by Cupriavidus necator H16 was investigated. Fed-batch cultivation mode in bioreactor was applied in this study. High cell dry weight (CDW) of 135.1 g/L, PHB content of 76.9 wt%, PHB productivity of 1.73 g/L/h, and PHB yield of 0.8 g/g were obtained from WCO. In the case of WFO, the CDW, PHB content, PHB productivity, and PHB yield were 114.8 g/L, 72.5 wt%, 1.73 g/L/h, and 0.92 g/g, respectively. The PHB productivity and yield obtained in the current study from WCO or WFO are among the highest reported so far for PHA production using oils as sole carbon substrate, suggesting that both WCO and WFO can be used as inexpensive carbon substrates for the production of PHA on an industrial scale.

Valorisation of waste cooking oil using mixed culture into short- and medium-chain length polyhydroxyalkanoates: Effect of concentration, temperature and ammonium

The production of polyhydroxyalkanoates (PHAs) from waste cooking oil (WCO) by a mixed culture was investigated in the present study at increasing WCO concentrations, temperature and ammonium availability. The PHA production was done in two steps: in the first step, a mixed culture was enriched in PHA-accumulating bacteria from activated sludge in a sequencing batch reactor operated in a feast-famine mode and in the second step the PHA accumulation by the enriched mixed culture was assessed in a batch reactor. In the enrichment step, two substrates, WCO and nonanoic acid were used for enrichment and in the PHA accumulation step only WCO was used. It was not possible to enrich a mixed culture in PHA-accumulating bacteria using WCO as substrate due to the development of filamentous bacteria causing foam formation and bulking in the reactor. However, our results showed that the mixed culture continuously fed with nonanoic acid was enriched in PHA-accumulating bacteria. This enriched culture accumulated both scl- and mcl-PHA using WCO as substrate. The maximum PHA accumulation capacity of this mixed culture from WCO was 38.2% cdw. Increasing the temperature (30-40 ℃) or WCO concentrations (5-20 g/l) increased the PHA accumulation capacity of the mixed culture and the ratios of scl-PHA to mcl-PHA. The presence of ammonium increased PHA accumulation (21.9% cdw) compared to the complete absence of ammonium (5.8% cdw). The thermal characterization of the PHA exhibited the advantageous properties of both scl- and mcl-PHA, i.e., higher melting temperature (152-172 ℃) similar to scl-PHA and a lower degree of crystallinity (12%) similar to mcl-PHA. This is the first study to report the potential of open mixed culture to produce scl- and mcl-PHA from WCO and thus contributing to the understanding of sustainable polymer production.

Simultaneous biosynthesis of bacterial polyhydroxybutyrate (PHB) and extracellular polymeric substances (EPS): Process optimization and Scale-up

Owing to their biodegradability and renewability, biopolymers are being employed in industrial and bio-medical sectors as sustainable alternatives to chemical based polymers. In the present study, isolated Providencia sp. depicted dual production of intra and extracellular biopolymers, polyhydroxybutyrate (PHB) and extracellular polymeric substances (EPS), respectively. The polymer production process was optimised by varying process parameters such as carbon load (20, 30 and 40 g L^-1) and pH (6, 7 and 8) for enhancing PHB and EPS productivity. Maximum yield of both PHB (2.62 g L^-1) and EPS (3.92 g L^-1) was observed with carbon load of 30 g L^-1 at pH 7. Scale-up studies were performed with optimized conditions and PHB and EPS production of 2.62 g L^-1 and 3.91 g L^-1, respectively was observed. The extracted EPS and PHB were characterized using FT-IR, FE-SEM-EDX, H¹ and C¹³ NMR and fluorescence microscopy.

A review on the potential of polyhydroxyalkanoates production from oil-based substrates

Polyhydroxyalkanoate (PHA) is a type of polyesters produced in the form of accumulated intracellular granules by many microorganisms. It is viewed as an environmentally friendly bioproduct due to its biodegradability and biocompatibility. The production of the PHA using oil substrates such as waste oil and plant oil, has gained considerable attention due to the high product yield and lower substrate cost. Nevertheless, the PHA fermentation using oil substrate is complicated due to the heterogenous fatty acid composition, varied bio-accessibility and possible inhibitory effect on the bacterial culture. This review presents the current state-of-the-art of PHA production from oil-based substrates. This paper firstly discusses the technical details, such as the choice of bacteria strain and fermentation conditions, characteristic of the oil substrate as well as the PHA composition and application. Finally, the paper discusses the challenges and prospects for up-scaling towards a cleaner and effective bioprocess. From the literature review, depending on the cell culture and the type of PHA produced, the oil platform can have a PHA yield of 0.2-0.8 g PHA/g oil substrate, with PHA content mostly from 40 to 90% of the cell dry weight. There is an on-going search for more effective oil-utilising PHA producers and lower cost substrate for effective PHA production. The final application of the PHA polymer influences the treatment needed during downstream processing and its economic performance. PHA with different compositions exhibits varied decomposition behaviour under different conditions, requiring further insight towards its management towards a sustainable circular economy.

Recent Advances in the Biosynthesis of Polyhydroxyalkanoates from Lignocellulosic Feedstocks

Polyhydroxyalkanoates (PHA) are biodegradable polymers that are considered able to replace synthetic plastic because their biochemical characteristics are in some cases the same as other biodegradable polymers. However, due to the disadvantages of costly and non-renewable carbon sources, the production of PHA has been lower in the industrial sector against conventional plastics. At the same time, first-generation sugar-based cultivated feedstocks as substrates for PHA production threatens food security and considerably require other resources such as land and energy. Therefore, attempts have been made in pursuit of suitable sustainable and affordable sources of carbon to reduce production costs. Thus, in this review, we highlight utilising waste lignocellulosic feedstocks (LF) as a renewable and inexpensive carbon source to produce PHA. These waste feedstocks, second-generation plant lignocellulosic biomass, such as maize stoves, dedicated energy crops, rice straws, wood chips, are commonly available renewable biomass sources with a steady supply of about 150 billion tonnes per year of global yield. The generation of PHA from lignocellulose is still in its infancy, hence more screening of lignocellulosic materials and improvements in downstream processing and substrate pre-treatment are needed in the future to further advance the biopolymer sector.

Recent approaches for enhanced production of microbial polyhydroxybutyrate: Preparation of biocomposites and applications

In modern decades, an increase in environmental awareness has attracted the keen interest of researchers to investigate eco-sustainable, recyclable materials to minimize reliance on petroleum-based polymeric compounds. Poly (3-hydroxybutyrate) is amorphous, linear, and biodegradable bacterial polyesters that belong to the polyhydroxyalkanoates family with enormous applications in many fields. The present review provides comprehensive information on polyhydroxybutyrate production from different biomass feedstock. Various studies on PHB production by genetically engineered bacterial cells and optimization of parameters have been discussed. Recent technological innovation in processing polyhydroxybutyrate-based biocomposite through the different process has also been examined. Besides this, the potential applications of the derived competent biocomposites in the other fields have been depicted.

Valorization of waste-cooking oil into sophorolipids and application of their methyl hydroxyl branched fatty acid derivatives to produce engineering bioplastics

Waste-cooking oil (WCO) is defined as vegetable oil that has been used to fry food at high temperatures. The annual global generation of WCO is 41-67 million tons. Without proper treatment, most WCO is abandoned in sinks and the solid residue of WCO is disposed of in landfills, resulting in serious environmental problems. Recycling and valorizing WCO have received considerable attention to reduce its negative impact on ecosystems. To convert WCO into a high value-added compound, we aimed to produce sophorolipids (SLs) that are industrially important biosurfactants, using WCO as a hydrophobic substrate by the fed-batch fermentation of Starmerella bombicola. The SLs concentration was increased ~3.7-fold compared with flask culture (315.6 vs. 84.8 g/L), which is the highest value ever generated from WCO. To expand the applications of SLs, we prepared methyl hydroxy branched fatty acids (MHBFAs) from SLs, which are important chemicals for various industries yet difficult to produce by chemical methods, using a bio-chemical hybrid approach. We synthesized bio-based plastics using MHBFAs as co-monomers. Compared with the control polymer without MHBFAs, even the incorporation of 1 mol% into polymer chains improved mechanical properties (such as ultimate tensile strength, 1.1-fold increase; toughness, 1.3-fold increase). To the best of our knowledge, this is the first attempt to apply MHBFAs from SLs derived from WCO to building blocks of plastics. Thus, we extended the valorization areas of WCO to one of the world's largest industries.

A comprehensive overview and recent advances on polyhydroxyalkanoates (PHA) production using various organic waste streams

Polyhydroxyalkanoates (PHA) are appealing as an important alternative to replace synthetic plastics owing to its comparable physicochemical properties to that of synthetic plastics, and biodegradable and biocompatible nature. This review gives an inclusive overview of the current research activities dealing with PHA production by utilizing different waste fluxes generated from food, milk and sugar processing industries. Valorization of these waste fluxes makes the process cost effective and practically applicable. Recent advances in the approaches adopted for waste treatment, fermentation strategies, and genetic engineering can give insights to the researchers for future direction of waste to bioplastics production. Lastly, synthesis and application of PHA-nanocomposites, research and development challenges, future perspectives for sustainable and cost-effective PHB production are also discussed. In addition, the review addresses the useful information about the opportunities and confines associated with the sustainable PHA production using different waste streams and their evaluation for commercial implementation within a biorefinery.

Valorization of agro-wastes for the biosynthesis and characterization of polyhydroxybutyrate by Bacillus sp. isolated from rice bran dumping yard

Investigations have been made to determine the usage of inexpensive agro-waste products as an alternative carbon source for the production of degradable bacterial polyester. Among 33 bacterial isolates, a gram-positive bacterium PPECLRB-16 isolated from rice bran dumping yard was found to accumulate a relatively higher quantity of PHB and identified as Bacillus sp. through 16S rRNA gene sequence analysis. The higher PHB producing bacterial isolate was grown with different inexpensive agro-wastes to determine the suitable carbon source for its growth and PHB production. The one-factor-at-a-time approach comparatively enhanced PHB yield (5.64 g/L) when grown for 48 h with 1.5% (w/v) of defatted oil cake at a pH of 7.0. The bacterially accumulated PHB was isolated from the cells, purified, and characterized using solid-state ¹³C NMR, FT-IR, Powder XRD, TGA, GPC, Tensile and HR-SEM analyses. The hydrophobicity and printing accessibility of recovered PHB were demonstrated using contact angle measurement by coating on different surfaces. The results obtained in the present investigation have thrown light on the potential usage of agro-waste by-products, mainly oil cake, as an appropriate carbon source for the commercial production of PHB by Bacillus sp. in a cost-effective way.

The role of biotechnology in the transition from plastics to bioplastics: an opportunity to reconnect global growth with sustainability

Building new value chains, through the valorization of biomass components for the development of innovative bio‐based products (BBPs) aimed at specific market sectors, will accelerate the transition from traditional production technologies to the concept of biorefineries. Recent studies aimed at mapping the most relevant innovations undergoing in the field of BBPs (Fabbri et al. 2019, Final Report of the Task 3 BIOSPRI Tender Study on Support to R&I Policy in the Area of Bio‐based Products and Services, delivered to the European Commission (DG RTD)), clearly showed the dominant position played by the plastics sector, in which new materials and innovative technical solutions based on renewable resources, concretely contribute to the achievement of relevant global sustainability goals. New sustainable solutions for the plastic sector, either bio‐based or bio‐based and biodegradable, have been intensely investigated in recent years. The global bioplastics and biopolymers market size is expected to grow from USD 10.5 billion in 2020 to USD 27.9 billion by 2025 (Markets and Markets, 2020, Bioplastics & Biopolymers Market by Type (Non‐Biodegradable/Bio‐Based, Biodegradable), End‐Use Industry (Packaging, Consumer Goods, Automotive & Transportation, Textiles, Agriculture & Horticulture), Region ‐ Global Forecast to 2025), and this high growth is driven primarily by the growth of the global packaging end‐use industry. Such relevant opportunities are the outcomes of intensive scientific and technological research devoted to the development of new materials with selected technical features, which can represent feasible substitutes for the fossil‐based plastic materials currently used in the packaging sectors and other main fields. This article offers a map of the latest developments connected to the plastic sector, achieved through the application of biotechnological routes for the preparation of completely new polymeric structures, or drop‐in substitutes derived from renewable resources, and it describes the specific role played by biotechnology in promoting and making this transition faster.

Investigation of the Physiology of the Obligate Alkaliphilic Bacillus marmarensis GMBE 72T Considering Its Alkaline Adaptation Mechanism for Poly(3-hydroxybutyrate) Synthesis

The novel extreme obligate alkaliphilic Bacillus marmarensis DSM 21297 is known to produce polyhydroxybutyrate (PHB). However, the detailed mechanism of PHB synthesis in B. marmarensis is still unknown. Here, we investigated which metabolic pathways and metabolic enzymes are responsible for PHB synthesis in order to understand the regulatory pathway and optimize PHB synthesis in B. marmarensis. In accordance with the fact that beta-galactosidase, 3-hydroxyacyl-CoA dehydrogenase, and Enoyl-CoA hydratase together with acyl-CoA dehydrogenase and lipase were annotated in B. marmarensis according to the RAST server, we used glucose, lactose, and olive oil to understand the preferred metabolic pathway for the PHB synthesis. It was found that B. marmarensis produces PHB from glucose, lactose, and olive oil. However, the highest PHB titer and the highest amount of PHB synthesized per dry cell mass (Y_P/X) were achieved in the presence of lactose, as compared to glucose and olive oil. Additionally, in the absence of peptone, the amount of PHB synthesized is reduced for each carbon source. Interestingly, none of the carbon sources studied yielded an efficient PHB synthesis, and supplementation of the medium with potassium ions did not enhance PHB synthesis. According to these experimental results and the presence of annotated metabolic enzymes based on the RAST server, PHB accumulation in the cells of B. marmarensis could be improved by the level of the expression of 3-hydroxybutyryl-CoA dehydrogenase (1.1.1.157), which increases the production of NADPH. Additionally, the accumulation of 3-hydroxyacyl-CoA could enhance the production of PHB in B. marmarensis in the presence of fatty acids. To our knowledge, this is the first report investigating the regulatory system involved in the control of PHB metabolism of B. marmarensis.

Biosynthesis of Polyhydroxyalkanoates from Defatted Chlorella Biomass as an Inexpensive Substrate

Microalgae biomass has been recently used as an inexpensive substrate for the industrial production of polyhydroxyalkanoates (PHAs). In this work, a dilute acid pretreatment using 0.3 N of hydrochloric acid (HCl) was performed to extract reducing sugars from 10% (w/v) of defatted Chlorella biomass (DCB). The resulting HCl DCB hydrolysate was used as a renewable substrate to assess the ability of three bacterial strains, namely Bacillus megaterium ALA2, Cupriavidus necator KCTC 2649, and Haloferax mediterranei DSM 1411, to produce PHA in shake flasks. The results show that under 20 g/L of DCB hydrolysate derived sugar supplementation, the cultivated strains successfully accumulated PHA up to 29.7–75.4% of their dry cell weight (DCW). Among the cultivated strains, C. necator KCTC 2649 exhibited the highest PHA production (7.51 ± 0.20 g/L, 75.4% of DCW) followed by H. mediterranei DSM 1411 and B. megaterium ALA2, for which a PHA content of 3.79 ± 0.03 g/L (55.5% of DCW) and 0.84 ± 0.06 g/L (29.7% of DCW) was recorded, respectively. Along with PHA, a maximum carotenoid content of 1.80 ± 0.16 mg/L was produced by H. mediterranei DSM 1411 at 120 h of cultivation in shake flasks. PHA and carotenoid production increased by 1.45- and 1.37-fold, respectively, when HCl DCB hydrolysate biotransformation was upscaled to a 1 L of working volume fermenter. Based on FTIR and 1H NMR analysis, PHA polymers accumulated by B. megaterium ALA2 and C. necator KCTC 2649 were identified as homopolymers of poly(3-hydroxybutyrate). However, a copolymer of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with a 3-hydroxyvalerate fraction of 10.5 mol% was accumulated by H. mediterranei DSM 1411.

Polyhydroxyalkanoate and its efficient production: an eco-friendly approach towards development

Polyhydroxyalkanoate (PHA) is the most promising solution to major ecological problem of plastic accumulation. The biodegradable and biocompatible properties of PHA make it highly demanding in the biomedical and agricultural field. The limited market share of PHA industries despite having tremendous demand as concerned with environment has led to knock the doors of scientific research for finding ways for the economic production of PHA. Therefore, new methods of its production have been applied such as using a wide variety of feedstock like organic wastes and modifying PHA synthesizing enzyme at molecular level. Modifying metabolic pathways for PHA production using new emerging techniques like CRISPR/Cas9 technology has simplified the process spending less amount of time. Using green solvents under pressurized conditions, ionic liquids, supercritical solvents, hypotonic cell disintegration for release of PHA granules, switchable anionic surfactants and even digestion of non-PHA biomass by animals are some novel strategies for PHA recovery which play an important role in sustainable production of PHA. Hence, this review provides a view of recent applications, significance of PHA and new methods used for its production which are missing in the available literature.

Statistical augmentation of polyhydroxybutyrate production by Isoptericola variabilis: Characterization, moulding, in vitro cytocompatibility and biodegradability evaluation

This study aimed to explore the production of polyhydroxybutyrate (PHB), a polyhydroxyalkanoate (PHA), which has been widely considered as a potential substitute for the synthetic polymers. Among 53 actinomycete isolates, 11 of them were found to be PHB positive and the quantity of PHB from the positive isolates varied from 10.5 to 29.82 wt% on a dry cell weight basis. A strain designated as PPLAT 012, accumulated relatively higher PHB and has been identified as Isoptericola variabilis by 16S rRNA gene sequence analysis. An effort has also been made to optimize the PHB production by the hyper-producing strain using the conventional, one-factor-at-a-time, and statistical response surface methodologies and the maximum PHB production (46.18%) in DSMZ medium, amended with 12% glucose and 9% potassium nitrate with a pH of 7.0. Further, the characteristic properties such as processability, cytocompatibility and biodegradability of the extracted PHB was also demonstrated. The physical properties of the recovered PHB was further improved by blending with PLA and the resultant blends were characterized. The present investigation has demonstrated that the isolate, Isoptericola variabilis, could be utilized as a potential source for the production of PHB with desirable characteristics, suitable for biomedical applications.

Utilization of food waste streams for the production of biopolymers

Uncontrolled decomposition of agro-industrial waste leads to extensive contamination of water, land, and air. There is a tremendous amount of waste from various sources which causes serious environmental problems. The concern in the disposal problems has stimulated research interest in the valorization of waste streams. Valorization of the wastes not only reduces the volume of waste but also reduces the contamination to the environment. Waste from food industries has great potential as primary or secondary feedstocks for biopolymer production by extraction or fermentation with pre-treatment or without pre-treatment by solid-state fermentation to obtain fermentable sugars. Various types of waste can be used as substrates for the production of biomaterials but recently more focus has been observed on the agro-industrial wastes which have a high rate of production worldwide. This review collates in detail the different food wastes used for biopolymer, technologies for the production and characterization of the biopolymers, and their economic/technical viability.

Critical overview of biomass feedstocks as sustainable substrates for the production of polyhydroxybutyrate (PHB)

Polyhydroxybutyrates (PHBs) are a class of biopolymers produced by different microbial species and are biodegradable and biocompatible in nature as opposed to petrochemically derived plastics. PHBs have advanced applications in medical sector, packaging industries, nanotechnology and agriculture, among others. PHB is produced using various feedstocks such as glycerol, dairy wastes, agro-industrial wastes, food industry waste and sugars. Current focus on PHB research has been primarily on reducing the cost of production and, on downstream processing to isolate PHB from cells. Recent advancements to improve the productivity and quality of PHB include genetic modification of producer strain and modification of PHB by blending to develop desirable properties suited to diversified applications. Selection of feedstock plays a critical role in determining the economic feasibility and sustainability of the process. This review provides a bird's eye view of the suitability of different waste resources for producing polyhydroxybutyrate; providing state-of the art information and analysis.

Can Polyhydroxyalkanoates Be Produced Efficiently From Waste Plant and Animal Oils?

Polyhydroxyalkanoates (PHAs) are a potential replacement for some petrochemical-based plastics. PHAs are polyesters synthesized and stored by various bacteria and archaea in their cytoplasm as water-insoluble inclusions. PHAs are usually produced when the microbes are cultured with nutrient-limiting concentrations of nitrogen, phosphorus, sulfur, or oxygen and excess carbon sources. Such fermentation conditions have been optimized by industry to reduce the cost of PHAs produced commercially. Industrially, these biodegradable polyesters are derived from microbial fermentation processes utilizing various carbon sources. One of the major constraints in scaling-up PHA production is the cost of the carbon source metabolized by the microorganisms. Hence, cheap and renewable carbon substrates are currently being investigated around the globe. Plant and animal oils have been demonstrated to be excellent carbon sources for high yield production of PHAs. Waste streams from oil mills or the used oils, which are even cheaper, are also used. This approach not only reduces the production cost for PHAs, but also makes a significant contribution toward the reduction of environmental pollution caused by the used oil. Advancements in the genetic and metabolic engineering of bacterial strains have enabled a more efficient utilization of various carbon sources, in achieving high PHA yields with specified monomer compositions. This review discusses recent developments in the biosynthesis and classification of various forms of PHAs produced using crude and waste oils from the oil palm and fish industries. The biodegradability of the PHAs produced from these oils will also be discussed.

Metabolic Rearrangements Causing Elevated Proline and Polyhydroxybutyrate Accumulation During the Osmotic Adaptation Response of Bacillus megaterium

For many years now, Bacillus megaterium serves as a microbial workhorse for the high-level production of recombinant proteins in the g/L-scale. However, efficient and stable production processes require the knowledge of the molecular adaptation strategies of the host organism to establish optimal environmental conditions. Here, we interrogated the osmotic stress response of B. megaterium using transcriptome, proteome, metabolome, and fluxome analyses. An initial transient adaptation consisted of potassium import and glutamate counterion synthesis. The massive synthesis of the compatible solute proline constituted the second longterm adaptation process. Several stress response enzymes involved in iron scavenging and reactive oxygen species (ROS) fighting proteins showed higher levels under prolonged osmotic stress induced by 1.8 M NaCl. At the same time, the downregulation of the expression of genes of the upper part of glycolysis resulted in the activation of the pentose phosphate pathway (PPP), generating an oversupply of NADPH. The increased production of lactate accompanied by the reduction of acetate secretion partially compensate for the unbalanced (NADH/NAD⁺) ratio. Besides, the tricarboxylic acid cycle (TCA) mainly supplies the produced NADH, as indicated by the higher mRNA and protein levels of involved enzymes, and further confirmed by ¹³C flux analyses. As a consequence of the metabolic flux toward acetyl-CoA and the generation of an excess of NADPH, B. megaterium redirected the produced acetyl-CoA toward the polyhydroxybutyrate (PHB) biosynthetic pathway accumulating around 30% of the cell dry weight (CDW) as PHB. This direct relation between osmotic stress and intracellular PHB content has been evidenced for the first time, thus opening new avenues for synthesizing this valuable biopolymer using varying salt concentrations under non-limiting nutrient conditions.

Facile Preparation of Porous Microfiber from Poly-3-(R)-Hydroxybutyrate and Its Application

In this study, we described the development of a simplified wet spinning method of the production of a novel type of porous continuous fiber based on poly-3-(R)-hydroxybutyrate (PHB). The principle of this method is precipitation of PHB dissolved in chloroform solution into the ethanol precipitation bath. The influence of various PHB concentrations and feed rates on specific surface area (measured by nitrogen absorption method) was studied. Materials were also characterized by SEM. Surface areas of fibers achieved by wet spinning were in the range of tens of m².g^-1, and the biggest surface area value was 55 m².g^-1. The average diameter of fibers was in the range of 20-120 μm and was dependent on both PHB concentration and feed rate. Optimum conditions for reaching stable fibers of high surface area were 3-5 % w.t. of PHB and feed rate 0.5-3 ml.h^-1. Fibers were functionalized by adsorption of some natural plant extracts. The incorporation of active substances into fibers was confirmed by infrared spectroscopy. High antioxidant and antimicrobial effect of PHB-fibers with cloves extract was found, as well as excellent long-term stability and optimal dynamics of the release of active compounds. The newly produced material would be applicable in pharmacy, cosmetics, and wound healing.

Biotechnological Production of Poly(3-Hydroxybutyrate-co-4-Hydroxybutyrate-co-3-Hydroxyvalerate) Terpolymer by Cupriavidus sp. DSM 19379

The terpolymer of 3-hydroxybutyrate (3HB), 3-hydroxyvalerate (3HV), and 4-hydroxybutyrate (4HB) was produced employing Cupriavidus sp. DSM 19379. Growth in the presence of γ-butyrolactone, ε-caprolactone, 1,4-butanediol, and 1,6-hexanediol resulted in the synthesis of a polymer consisting of 3HB and 4HB monomers. Single and two-stage terpolymer production strategies were utilized to incorporate the 3HV subunit into the polymer structure. At the single-stage cultivation mode, γ-butyrolactone or 1,4-butanediol served as the primary substrate and propionic and valeric acid as the precursor of 3HV. In the two-stage production, glycerol was used in the growth phase, and precursors for the formation of the terpolymer in combination with the nitrogen limitation in the medium were used in the second phase. The aim of this work was to maximize the Polyhydroxyalkanoates (PHA) yields with a high proportion of 3HV and 4HB using different culture strategies. The obtained polymers contained 0–29 mol% of 3HV and 16–32 mol% of 4HB. Selected polymers were subjected to a material properties analysis such as differential scanning calorimetry (DSC), thermogravimetry, and size exclusion chromatography coupled with multi angle light scattering (SEC-MALS) for determination of the molecular weight. The number of polymers in the biomass, as well as the monomer composition of the polymer were determined by gas chromatography.

Preparation and characterization of polyhydroxybutyrate-co-valerate (PHBV) as green composites using nano reinforcements

This article presents the preparation and characterization of polyhydroxybutyrate-co-valerate (PHBV) nanocomposite films containing cellulose nanocrystals (CNC) and aluminum oxide nanoparticles (Al₂O₃) as reinforcements. The effects of adding nanoparticles on the mechanical properties, such as tensile strength and elongation, were studied using dynamic-mechanical analysis (DMA) such as modulus and tan δ. Also, morphology and thermal features were investigated by scanning electron microscopy (SEM) and differential scanning calorimetry (DSC), respectively. For this purpose, first, CNC and Al₂O₃ with a ratio of 0, 1, 3 and 5 wt% was added to a biopolymer, then a combination of these two with the ratio of 3:3 and 5:5 was added to the PHBV matrix, separately; and finally, the various nanocomposite films were prepared by the solvent casting method. After adding nanoparticles, the tensile strength and thermal stability of the PHBV/CNC films increased and the elongation decreased. SEM observations showed that large amounts of nanoparticles (3 wt%) are strongly agglomerated in the biopolymer matrix. This led to a decrease of mechanical properties in the composites with nanoparticles of more than 3% by weight. DSC results showed that the glass transition temperature (T_g) increased slightly with the incorporation of nano participles to PHBV. The enthalpy of fusion (ΔH_fus) increased from 33.8 J/g for neat PHBV film to 48.1, 50 and 45.8 J/g for PHBV films containing 1, 3, and 5 wt% CNC, respectively. These results are consistent with the conclusions of DMA. The improvement of physical and mechanical properties of the composites confirmed that CNC has a better effect than aluminum oxide nanoparticles as a nano reinforcement.

Production of bioplastic through food waste valorization

The tremendous amount of food waste from diverse sources is an environmental burden if disposed of inappropriately. Thus, implementation of a biorefinery platform for food waste is an ideal option to pursue (e.g., production of value-added products while reducing the volume of waste). The adoption of such a process is expected to reduce the production cost of biodegradable plastics (e.g., compared to conventional routes of production using overpriced pure substrates (e.g., glucose)). This review focuses on current technologies for the production of polyhydroxyalkanoates (PHA) from food waste. Technical details were also described to offer clear insights into diverse pretreatments for preparation of raw materials for the actual production of bioplastic (from food wastes). In this respect, particular attention was paid to fermentation technologies based on pure and mixed cultures. A clear description on the chemical modification of starch, cellulose, chitin, and caprolactone is also provided with a number of case studies (covering PHA-based products) along with a discussion on the prospects of food waste valorization approaches and their economic/technical viability.

High Cell Density Conversion of Hydrolysed Waste Cooking Oil Fatty Acids Into Medium Chain Length Polyhydroxyalkanoate Using Pseudomonas putida KT2440

Waste cooking oil (WCO) is a major pollutant, primarily managed through incineration. The high cell density bioprocess developed here allows for better use of this valuable resource since it allows the conversion of WCO into biodegradable polymer polyhydroxyalkanoate (PHA). WCO was chemically hydrolysed to give rise to a mixture of fatty acids identical to the fatty acid composition of waste cooking oil. A feed strategy was developed to delay the stationary phase, and therefore achieve higher final biomass and biopolymer (PHA) productivity. In fed batch (pulse feeding) experiments Pseudomonas putida KT2440 achieved a PHA titre of 58 g/l (36.4% of CDW as PHA), a PHA volumetric productivity of 1.93 g/l/h, a cell density of 159.4 g/l, and a biomass yield of 0.76 g/g with hydrolysed waste cooking oil fatty acids (HWCOFA) as the sole substrate. This is up to 33-fold higher PHA productivity compared to previous reports using saponified palm oil. The polymer (PHA) was sticky and amorphous, most likely due to the long chain monomers acting as internal plasticisers. High cell density cultivation is essential for the majority of industrial processes, and this bioprocess represents an excellent basis for the industrial conversion of WCO into PHA.