Fermentation of lactose to ethanol in cheese whey permeate and concentrated permeate by engineered Escherichia coli

Evaluation of Kluyveromyces spp. for conversion of lactose in different types of whey from dairy processing waste into ethanol

The processing of dairy products currently generates significant amounts of waste, particularly in the form of liquid whey. The disposal of whey poses a challenge to the environment due to its high organic content and biological oxygen demand. Whey contains lactose, soluble proteins, lipids, and minerals. While Saccharomyces cerevisiae can efficiently utilize glucose, they are unable to metabolize lactose. In contrast, Kluyveromyces spp. encode two genes, Lac12 and Lac4 that enable conversion of lactose to other by-products such as ethanol. Here, we selected five Kluyveromyces yeast inoculated into three different types of whey substrates, cheddar sweet whey, cream cheese acid whey, and yogurt acid whey that could be used to convert lactose into ethanol. We demonstrate that differences exist in ethanol production across different whey substrates inoculated with Kluyveromyces yeast. In sweet whey, K. lactis, K. lactis Y-1205 and K. lactis Y-1564 were the highest ethanol producing strains. The highest amount of ethanol produced was 24.85 ± 3.5 g/L achieved by Y-1564 in sweet whey (96.8% efficiency). K. lactis Y-1205 produced 22.39 ± 5.6 g/L ethanol in yogurt acid whey. In cream cheese acid whey, K. lactis strains produced significantly higher ethanol levels compared to S. cerevisiae and K. marxianus (p < 0.05). Outcomes from this study could provide a simple and cheap solution for small-to medium-sized dairy processing facilities to ferment lactose in whey into ethanol using lactose-consuming yeasts.

Valorisation of Whey Permeate in Sequential Bioprocesses towards Value-Added Products-Optimisation of Biphasic and Classical Batch Cultures of Kluyveromyces marxianus

Whey permeate is categorised as hazardous wastewater for aquatic environments, mainly due to its high lactose content. Therefore, it must be valorised before being released into the environment. One pathway for whey permeate management is its use in biotechnological processes. Herein, we present roads for whey permeate valorisation with the K. marxianus WUT240 strain. The established technology is based on two bioprocesses. During first, 2.5 g/L 2-phenylethanol and fermented plant oils enriched with different flavourings are obtained after 48 h biphasic cultures at 30 °C. The second process leads to a maximum of 75 g ethanol/L (Y_P/S = 0.53 g/g) after 96 h at 30 °C. Moreover, established whey permeate valorisation pathways reduced its biochemical oxygen demand and chemical oxygen demand values by 12- to 3-fold, respectively. Together, the present study reports a complete, effective, and environmentally friendly whey permeate management strategy while simultaneously enabling the acquisition of valuable compounds with substantial application potential.

Design of a stable ethanologenic bacterial strain without heterologous plasmids and antibiotic resistance genes for efficient ethanol production from concentrated dairy waste

Engineering sustainable bioprocesses that convert abundant waste into fuels is pivotal for efficient production of renewable energy. We previously engineered an Escherichia coli strain for optimized bioethanol production from lactose-rich wastewater like concentrated whey permeate (CWP), a dairy effluent obtained from whey valorization processes. Although attractive fermentation performances were reached, significant improvements are required to eliminate recombinant plasmids, antibiotic resistances and inducible promoters, and increase ethanol tolerance. Here, we report a new strain with chromosomally integrated ethanologenic pathway under the control of a constitutive promoter, without recombinant plasmids and resistance genes. The strain showed extreme stability in 1-month subculturing, with CWP fermentation performances similar to the ethanologenic plasmid-bearing strain. We then investigated conditions enabling efficient ethanol production and sugar consumption by changing inoculum size and CWP concentration, revealing toxicity- and nutritional-related bottlenecks. The joint increase of ethanol tolerance, via adaptive evolution, and supplementation of small ammonium sulphate amounts (0.05% w/v) enabled a fermentation boost with 6.6% v/v ethanol titer, 1.2 g/L/h rate, 82.5% yield, and cell viability increased by three orders of magnitude. Our strain has attractive features for industrial settings and represents a relevant improvement in the existing ethanol production biotechnologies.

High-Gravity Fermentation for Bioethanol Production from Industrial Spent Black Cherry Brine Supplemented with Whey

By-products from different industries could represent an available source of carbon and nitrogen which could be used for bioethanol production using conventional Saccharomyces cerevisiae yeast. Spent cherry brine and whey are acid food by-products which have a high organic matter content and toxic compounds, and their discharges represent significant environmental and economic challenges. In this study, different combinations of urea, yeast concentrations, and whey as a nutrient source were tested for bioethanol production scale-up using 96-well microplates as well as 7.5 L to 100 L bioreactors. For bioethanol production in vials, the addition of urea allowed increasing the bioethanol yield by about 10%. Bioethanol production in the 7.5 L and 100 L bioreactors was 73.2 g·L−1 and 103.5 g·L−1 with a sugar consumption of 81.5% and 94.8%, respectively, using spent cherry brine diluted into whey (200 g·L−1 of total sugars) supplemented with 0.5 g·L−1 urea and 0.5 g·L−1 yeast at 30 °C and a pH of 5.0 after 96 h of fermentation for both systems. The results allow these by-products to be considered low-economic-value alternatives for fuel- or food-grade bioethanol production.

Bioengineered microbial platforms for biomass-derived biofuel production - A review

Global warming issues, rapid fossil fuel diminution, and increasing worldwide energy demands have diverted accelerated attention in finding alternate sources of biofuels and energy to combat the energy crisis. Bioconversion of lignocellulosic biomass has emerged as a prodigious way to produce various renewable biofuels such as biodiesel, bioethanol, biogas, and biohydrogen. Ideal microbial hosts for biofuel synthesis should be capable of using high substrate quantity, tolerance to inhibiting substances and end-products, fast sugar transportation, and amplified metabolic fluxes to yielding enhanced fermentative bioproduct. Genetic manipulation and microbes' metabolic engineering are fascinating strategies for the economical production of next-generation biofuel from lignocellulosic feedstocks. Metabolic engineering is a rapidly developing approach to construct robust biofuel-producing microbial hosts and an important component for future bioeconomy. This approach has been widely adopted in the last decade for redirecting and revamping the biosynthetic pathways to obtain a high titer of target products. Biotechnologists and metabolic scientists have produced a wide variety of new products with industrial relevance through metabolic pathway engineering or optimizing native metabolic pathways. This review focuses on exploiting metabolically engineered microbes as promising cell factories for the enhanced production of advanced biofuels.

Kinetic analysis and modeling of L-valine production in fermentation batch from E. coli using glucose, lactose and whey as carbon sources

In this study the effect of the carbon source on L-valine production kinetics using genetically modified E. coli was researched. Glucose, lactose, Whey (W) and deproteinized whey (DW) were tested as carbon sources, keeping the carbon/nitrogen (C/N) ratio constant. Biomass generation and substrate consumption were modeled with Contois and Mass Conservation models, respectively, whereas Mass Conservation Balance and Luedeking-Piret models were used for product obtaining. Results showed that L-valine production is partially associated to growth, with values of 0.485 g L-valine/(g dry cell weight.h), and a product loss effect at a specific rate (β) of 0.019 g L-valine/(g dry cell weight.h) with W. The yield of this product increased 36 % using W concerning glucose or lactose as carbon sources. On the other hand, Mass Balance and Luedeking-Piret models adjust properly to experimental data (R2 >0.90). In conclusion whey is a promising substrate for obtaining L-valine using genetically-modified E. coli.

Whey Utilization: Sustainable Uses and Environmental Approach

The dairy industry produces large amounts of whey as a by- or co-product, which has led to considerable environmental problems due to its high organic matter content. Over the past decades, possibilities of more environmentally and economically efficient whey utilisation have been studied, primarily to convert unwanted end products into a valuable raw material. Sustainable whey management is mostly oriented to biotechnological and food applications for the development of value-added products such as whey powders, whey proteins, functional food and beverages, edible films and coatings, lactic acid and other biochemicals, bioplastic, biofuels and similar valuable bioproducts. This paper provides an overview of the sustainable utilization of whey and its constituents, considering new refining approaches and integrated processes to convert whey, or lactose and whey proteins to high value-added whey-based products.

Bioprospecting of microbial strains for biofuel production: metabolic engineering, applications, and challenges

The issues of global warming, coupled with fossil fuel depletion, have undoubtedly led to renewed interest in other sources of commercial fuels. The search for renewable fuels has motivated research into the biological degradation of lignocellulosic biomass feedstock to produce biofuels such as bioethanol, biodiesel, and biohydrogen. The model strain for biofuel production needs the capability to utilize a high amount of substrate, transportation of sugar through fast and deregulated pathways, ability to tolerate inhibitory compounds and end products, and increased metabolic fluxes to produce an improved fermentation product. Engineering microbes might be a great approach to produce biofuel from lignocellulosic biomass by exploiting metabolic pathways economically. Metabolic engineering is an advanced technology for the construction of highly effective microbial cell factories and a key component for the next-generation bioeconomy. It has been extensively used to redirect the biosynthetic pathway to produce desired products in several native or engineered hosts. A wide range of novel compounds has been manufactured through engineering metabolic pathways or endogenous metabolism optimizations by metabolic engineers. This review is focused on the potential utilization of engineered strains to produce biofuel and gives prospects for improvement in metabolic engineering for new strain development using advanced technologies.

Invited review: Acid whey trends and health benefits

In recent years, acid whey production has increased due to a growing demand for Greek yogurt and acid-coagulated cheeses. Acid whey is a dairy by-product for which the industry has long struggled to find a sustainable application. Bulk amounts of acid whey associated with the dairy industry have led to increasing research on ways to valorize it. Industry players are finding ways to use acid whey on-site with ultrafiltration techniques and biodigesters, to reduce transportation costs and provide energy for the facility. Academia has sought to further investigate practical uses and benefits of this by-product. Although modern research has shown many other possible applications for acid whey, no comprehensive review yet exists about its composition, utilization, and health benefits. In this review, the industrial trends, the applications and uses, and the potential health benefits associated with the consumption of acid whey are discussed. The proximal composition of acid whey is discussed in depth. In addition, the potential applications of acid whey, such as its use as a starting material in the production of fermented beverages, as growth medium for cultivation of lactic acid bacteria in replacement of commercial media, and as a substrate for the isolation of lactose and minerals, are reviewed. Finally, the potential health benefits of the major protein constituents of acid whey, bioactive phospholipids, and organic acids such as lactic acid are described. Acid whey has promising applications related to potential health benefits, ranging from antibacterial effects to cognitive development for babies to human gut health.

Technical integrative approaches to cheese whey valorization towards sustainable environment

Whey, a byproduct of cheese production, is often treated as an industrial dairy waste. A large volume of this product is disposed of annually due to inadequate bioconversion approaches. With its high pollutant load, disposal without pretreatment has raised a lot of environmental concerns alerting the need to seek optimal methods for adequately extracting and utilizing its organic content. In recent years, several techniques for whey valorization have emerged which may serve as interventionary measures against its environmental effects after disposal. In this review, we discuss five major approaches, by which whey can be converted into eco-friendly products, to significantly cut whey wastage. The approaches to whey valorization are therefore examined under the following perspectives: whey as a raw material for the production of bioethanol and prebiotic oligosaccharides via β-galactosidase and microbe catalyzed reactions, for the production of refined lactose as an excipient for pharmaceutical purposes, and the clinical significance of whey hydrolysates and their antifungal activity in food processing.

Metabolic engineering of E. coli for producing phloroglucinol from acetate

Phloroglucinol is a three-hydroxyl phenolic compound and has diverse physiological and pharmacological activities such as antivirus and anti-inflammatory activities. Chemical synthesis of phloroglucinol suffered from many drawbacks such as high cost and environmental pollution. To avoid the above issues, microbial phloroglucinol biosynthesis was successfully accomplished in this study, while the abundant and low-cost acetate was used as the main carbon source. Firstly, the toxicity of phloroglucinol was tested, and E. coli BL21(DE3) could tolerate 5 g/L phloroglucinol. The ability of phloroglucinol synthase (PhlD) for catalyzing malonyl-CoA to phloroglucinol was confirmed, and E. coli BL21(DE3) expressing PhlD and acetyl-CoA carboxylase (ACCase) could produce 1107 ± 12 mg/L phloroglucinol from glucose. Then, E. coli BL21(DE3) was engineered to utilize acetate to produce 228 ± 15 mg/L phloroglucinol. Then, the endogenous citrate synthase (GltA) which could catalyze oxaloacetate and acetyl-CoA generated from acetate to citrate was knocked down by CRISPRi system in order to enhance the carbon flux for phloroglucinol production, and the titer was improved to 284 ± 8 mg/L. This work demonstrated that acetate could be used as low-cost substrate to achieve the biosynthesis of phloroglucinol and provided an example of effective utilization of acetate.

The Potential Production of the Bioactive Compound Pinene Using Whey Permeate

Pinene is a secondary plant metabolite that has functional properties as a flavor additive as well as potential cognitive health benefits. Although pinene is present in low concentrations in several plants, it is possible to engineer microorganisms to produce pinene. However, feedstock cost is currently limiting the industrial scale-up of microbial pinene production. One potential solution is to leverage waste streams such as whey permeate as an alternative to expensive feedstocks. Whey permeate is a sterile-filtered dairy effluent that contains 4.5% weight/weight lactose, and it must be processed or disposed of due its high biochemical oxygen demand, often at significant cost to the producer. Approximately 180 million m3 of whey is produced annually in the U.S., and only half of this quantity receives additional processing for the recovery of lactose. Given that organisms such as recombinant Escherichia coli grow on untreated whey permeate, there is an opportunity for dairy producers to microbially produce pinene and reduce the biological oxygen demand of whey permeate via microbial lactose consumption. The process would convert a waste stream into a valuable coproduct. This review examines the current approaches for microbial pinene production, and the suitability of whey permeate as a medium for microbial pinene production.

Cheese Whey Processing: Integrated Biorefinery Concepts and Emerging Food Applications

Cheese whey constitutes one of the most polluting by-products of the food industry, due to its high organic load. Thus, in order to mitigate the environmental concerns, a large number of valorization approaches have been reported; mainly targeting the recovery of whey proteins and whey lactose from cheese whey for further exploitation as renewable resources. Most studies are predominantly focused on the separate implementation, either of whey protein or lactose, to configure processes that will formulate value-added products. Likewise, approaches for cheese whey valorization, so far, do not exploit the full potential of cheese whey, particularly with respect to food applications. Nonetheless, within the concept of integrated biorefinery design and the transition to circular economy, it is imperative to develop consolidated bioprocesses that will foster a holistic exploitation of cheese whey. Therefore, the aim of this article is to elaborate on the recent advances regarding the conversion of whey to high value-added products, focusing on food applications. Moreover, novel integrated biorefining concepts are proposed, to inaugurate the complete exploitation of cheese whey to formulate novel products with diversified end applications. Within the context of circular economy, it is envisaged that high value-added products will be reintroduced in the food supply chain, thereby enhancing sustainability and creating "zero waste" processes.

Biohydrogen and polyhydroxyalkanoates (PHA) as products of a two-steps bioprocess from deproteinized dairy wastes

In this study a two-steps bioprocess approach aimed at biohydrogen production via dark-fermentation, and polyhydroxyalkanoates-PHA production by mixed microbial cultures, was proposed to valorise two dairy-waste streams coming from cheese whey deproteinization (i.e. Ricotta cheese production and ultrafiltration). During the first step, the increase of OLR was tested, resulting in higher daily H₂ volume (3.47 and 5.07 NL H₂ d^-1 for second cheese whey-SCW and concentrated cheese whey permeate-CCWP) and organic acids production (14.6 and 12.6 g L^-1 d^-1 for SCW and CCWP) for both the substrates, keeping good conversion of sugars into H₂ (1.37 and 1.93 mol H₂ mol^-1 sugars for SCW and CCWP). During the second step, the organic acids were used for PHA production reaching high conversion yields for both the fermented streams (as average 0.74 ± 0.14 mg COD_PHA mg^-1 COD_OA-in), with a maximum polymer content of 62 ± 4.5 and 55.1 ± 1.3% (g PHA g^-1 VSS) for fermented SCW and fermented CCWP respectively. For the results reported, this study could be taken into consideration for larger scale application.

Ethanol Production from Cheese Whey and Expired Milk by the Brown Rot Fungus Neolentinus lepideus

The basidiomycete brown rot fungus Neolentinus lepideus is capable of assimilating and fermenting lactose to ethanol with a conversion yield comparable to those of lactose-fermenting yeasts. The ability of the fungus to ferment lactose is not influenced by the addition of glucose or calcium. Therefore, N. lepideus may be useful in ethanol production from materials composed mainly of lactose, such as cheese whey or expired cow’s milk. Whey is a by-product of cheese manufacturing, and approximately 50% of the total worldwide production of whey is normally disposed of without being utilized. We found that N. lepideus produced ethanol directly from cheese whey with a yield of 0.35 g of ethanol per gram of lactose consumed, and it also fermented expired milk containing lactose, protein, and fat with a similar yield. Our findings revealed that the naturally occurring basidiomycete fungus possesses a unique ability to produce ethanol from cheese whey and expired milk. Thus, N. lepideus may be useful in facilitating ethanol production from dairy wastes in a cost-effective and environmentally friendly manner.

Yeast screening and cell immobilization on inert supports for ethanol production from cheese whey permeate with high lactose loads

Eight yeast strains of the genera Saccharomyces and Kluyveromyces were screened to ferment high lactose-load cheese whey permeate (CWP) (>130 g/L lactose) without nutrient supplementation. The fermentation conditions (temperature, pH and time) were optimized to maximize the fermentation performance (ethanol titer, ethanol yield and lactose consumption) for the two preselected strains, K. marxianus DSM 5422 and S. cerevisiae Ethanol Red, using a response surface methodology (RSM). Under optimized conditions, K. marxianus DSM 5422 attained ethanol titers of 6% (v/v) in only 44 h. Moreover, the feasibility of immobilizing this strain on four different inorganic supports (plastic, glass and Tygon silicone Raschig rings and alumina beads) was assessed. Glass Raschig rings and alumina beads showed a more stable performance over time, yielding ethanol titers of 60 g/L during 1,000 hours, which remarkably reduces yeast cultivation costs. Results demonstrate the feasibility of using CWP for successful ethanol production in a simple and economical process, which represents an attractive alternative for waste treatment in dairy industries.

Food Byproducts as Sustainable Ingredients for Innovative and Healthy Dairy Foods

The valorization of food wastes and byproducts has become a major subject of research to improve the sustainability of the food chain. This narrative review provides an overview of the current trends in the use of food byproducts in the development of dairy foods. We revised the latest data on food loss generation, the group of byproducts most used as ingredients in dairy product development, and their function within the food matrix. We also address the challenges associated with the sensory properties of the new products including ingredients obtained from byproducts, and consumers' attitudes towards these sustainable novel dairy foods. Overall, 50 studies supported the tremendous potential of the application of food byproducts (mainly those from plant-origin) in dairy foods as ingredients. There are promising results for their utilization as food additives for technological purposes, and as sources of bioactive compounds to enhance the health-promoting properties of dairy products. However, food technologists, nutritionists and sensory scientists should work together to face the challenge of improving the palatability and consumer acceptance of these novel and sustainable dairy foods.

Cell-free prototyping strategies for enhancing the sustainable production of polyhydroxyalkanoates bioplastics

The polyhydroxyalkanoates (PHAs) are microbially-produced biopolymers that could potentially be used as sustainable alternatives to oil-derived plastics. However, PHAs are currently more expensive to produce than oil-derived plastics. Therefore, more efficient production processes would be desirable. Cell-free metabolic engineering strategies have already been used to optimize several biosynthetic pathways and we envisioned that cell-free strategies could be used for optimizing PHAs biosynthetic pathways. To this end, we developed several Escherichia coli cell-free systems for in vitro prototyping PHAs biosynthetic operons, and also for screening relevant metabolite recycling enzymes. Furthermore, we customized our cell-free reactions through the addition of whey permeate, an industrial waste that has been previously used to optimize in vivo PHAs production. We found that the inclusion of an optimal concentration of whey permeate enhanced relative cell-free GFPmut3b production by approximately 50%. In cell-free transcription-translation prototyping reactions, gas chromatography-mass spectrometry quantification of cell-free 3-hydroxybutyrate (3HB) production revealed differences between the activities of the Native ΔPhaC_C319A (1.18 ± 0.39 µM), C104 ΔPhaC_C319A (4.62 ± 1.31 µM) and C101 ΔPhaC_C319A (2.65 ± 1.27 µM) phaCAB operons that were tested. Interestingly, the most active operon, C104 produced higher levels of PHAs (or PHAs monomers) than the Native phaCAB operon in both in vitro and in vivo assays. Coupled cell-free biotransformation/transcription-translation reactions produced greater yields of 3HB (32.87 ± 6.58 µM), and these reactions were also used to characterize a Clostridium propionicum Acetyl-CoA recycling enzyme. Together, these data demonstrate that cell-free approaches complement in vivo workflows for identifying additional strategies for optimizing PHAs production.