Enhanced rhamnolipids production using a novel bioreactor system based on integrated foam-control and repeated fed-batch fermentation strategy

Recent progress in microbial biosurfactants production strategies: Applications, technological bottlenecks, and future outlook

Biosurfactants are surface-active compounds produced by numerous microorganisms. They have gained significant attention due to their wide applications in food, pharmaceuticals, cosmetics, agriculture, and environmental remediation. The production efficiency and yield of microbial biosurfactants have improved significantly through the development and optimization of different process parameters. This review aims to provide an in-depth analysis of recent trends and developments in microbial biosurfactant production strategies, including submerged, solid-state, and co-culture fermentation. Additionally, review discusses biosurfactants' applications, challenges, and future perspectives. It highlights their advantages over chemical surfactants, emphasizing their biodegradability, low toxicity, and diverse chemical structures. However, the critical challenges in commercializing include high production costs and low yield. Strategies like genetic engineering, process optimization, and downstream processing, have been employed to address these challenges. The review provides insights into current commercial producers and highlights future perspectives such as novel bioprocesses, efficient microbial strains, and exploring their applications in emerging industries.

Valorization of waste engine oil to mono- and di-rhamnolipid in a sustainable approach to circular bioeconomy

This study aims to valorize waste engine oil (WEO) for synthesizing economically viable biosurfactants (rhamnolipids) to strengthen the circular bioeconomy concept. It specifically focuses on investigating the influence of key bioprocess parameters, viz. agitation and aeration rates, on enhancing rhamnolipid yield in a fed-batch fermentation mode. The methodology involves conducting experiments in a stirred tank bioreactor (3 L) using Pseudomonas aeruginosa gi |KP 163922| as the test organism. Central composite design and response surface methodology (CCD-RSM) are employed to design the experiments and analyze the effects of agitation and aeration rates on various parameters, including dry cell biomass (DCBM), surface tension, tensoactivity, and rhamnolipid yield. It is also essential to determine the mechanistic pathway of biosurfactant production followed by the strain using complex hydrophobic substrates such as WEO. The study reveals that optimal agitation and aeration rates of 200 rpm and 1 Lpm result in the highest biosurfactant yield of 29.76 g/L with minimal surface tension (28 mN/m). Biosurfactant characterization using FTIR, 1H NMR, and UPLC-MS/MS confirm the presence of dominant molecular ion peaks m/z 543.9 and 675.1. This suggests that the biosurfactant is a mixture of mono- and di-rhamnolipids (RhaC10C10, RhaRhaC10C12:1, RhaRhaC12:1C10). The findings present a sustainable approach for biosurfactant production in a fed-batch bioreactor. This research opens the possibility of exploring the use of pilot or large-scale bioreactors for biosurfactant production in future investigations.

Glycolipids biosurfactants production using low-cost substrates for environmental remediation: progress, challenges, and future prospects

The production of renewable materials from alternative sources is becoming increasingly important to reduce the detrimental environmental effects of their non-renewable counterparts and natural resources, while making them more economical and sustainable. Chemical surfactants, which are highly toxic and non-biodegradable, are used in a wide range of industrial and environmental applications harming humans, animals, plants, and other entities. Chemical surfactants can be substituted with biosurfactants (BS), which are produced by microorganisms like bacteria, fungi, and yeast. They have excellent emulsifying, foaming, and dispersing properties, as well as excellent biodegradability, lower toxicity, and the ability to remain stable under severe conditions, making them useful for a variety of industrial and environmental applications. Despite these advantages, BS derived from conventional resources and precursors (such as edible oils and carbohydrates) are expensive, limiting large-scale production of BS. In addition, the use of unconventional substrates such as agro-industrial wastes lowers the BS productivity and drives up production costs. However, overcoming the barriers to commercial-scale production is critical to the widespread adoption of these products. Overcoming these challenges would not only promote the use of environmentally friendly surfactants but also contribute to sustainable waste management and reduce dependence on non-renewable resources. This study explores the efficient use of wastes and other low-cost substrates to produce glycolipids BS, identifies efficient substrates for commercial production, and recommends strategies to improve productivity and use BS in environmental remediation.

Enhancing rhamnolipid production through a two-stage fermentation control strategy based on metabolic engineering and nitrate feeding

Nitrate plays a crucial role in the high-efficient fermentation production of rhamnolipids (RLs). However, the underlying mechanism remains unclear. Firstly, by knocking out the restriction endonuclease PaeKI and utilizatiing the endogenous CRISPR-Cas-mediated single-plasmid recombineering system, a genome editing system for P. aeruginosa KT1115 has been established. Secondly, an engineered strain KT1115ΔpaeKIΔnirS was obtained with a 87% of reduction in nitric oxide (NO) accumulation and a 93% of reduction in RLs production, revealing the crucial role of NO signaling molecule produced from nitrate metabolism in RLs production. Finally, by combining metabolic engineering of the nitrate metabolism pathway with nitrogen feeding, a new two-stage fermentation process was developed. The fermentation production period was reduced from 168 h to 120 h while achieving a high yield of 0.8 g/g, and the average productivity increased by 55%. In all, this study provides a novel insights in the RLs biosynthesis and fermentation control strategy.

Improving rhamnolipids production using fermentation-foam fractionation coupling system: cell immobilization and waste frying oil emulsion

This work focused on the development of an inexpensive carbon source and the improvement of the fermentation-foam fractionation coupling system. The rhamnolipids production capacity of waste frying oil (WFO) was evaluated. The suitable bacterial cultivation of seed liquid and the addition amount of WFO was 16 h and 2% (v/v), respectively. A combined strategy of cell immobilization and oil emulsion avoid cell entrainment inside foam and improves the oil mass transfer rate. The immobilization conditions of bacterial cells into alginate-chitosan-alginate (ACA) microcapsules were optimized using the response surface method (RSM). Under the optimal conditions, rhamnolipids production using batch fermentation with immobilized strain reached 7.18 ± 0.23% g/L. WFO was emulsified into a fermentation medium using rhamnolipids as emulsifier (0.5 g/L). By monitoring dissolved oxygen, 30 mL/min was selected as a suitable air volumetric flow rate for fermentation-foam fractionation coupling operation. The total production and recovery percentage of rhamnolipids were 11.29 ± 0.36 g/L and 95.62 ± 0.38%, respectively.

Microbial conversion of agro-processing waste (peanut meal) to rhamnolipid by Pseudomonas aeruginosa: solid-state fermentation, water extraction, medium optimization and potential applications

The high cost and severe foam in rhamnolipid fermentation are still bottlenecks for its industrial production and application. Non-foaming production of rhamnolipid by Pseudomonas aeruginosa FA1 was explored in solid-state fermentation using the agro-processing waste (peanut meal) as low-cost substrate. An environmental-friendly extraction method was developed to harvest rhamnolipid from solid-state culture. Strain FA1 produced 265.4 ± 8.2 mg rhamnolipid using 10 g peanut meal. HPLC-MS results revealed that 7 rhamnolipid homologues were produced, mainly including Rha-C₈-C₁₀ and Rha-Rha-C₁₀-C₁₀. Nitrate was the optimal nitrogen source. Peanut meal, MgSO₄ and CaCl₂ were significant factors for rhamnolipid production in solid-state fermentation. Rhamnolipid production was enhanced 31 % using the solid-state medium optimized by response surface method. The produced rhamnolipid reduced water surface tension to 28.1 ± 0.2 mN/m with a critical micelle concentration of 70 mg/L. The crude oil was emulsified with an emulsification index of 75.56 ± 1.29 %. The growth of tested bacteria and fungi was inhibited.

Bacterial-derived surfactants: an update on general aspects and forthcoming applications

The search for sustainable alternatives to the production of chemicals using renewable substrates and natural processes has been widely encouraged. Microbial surfactants or biosurfactants are surface-active compounds synthesized by fungi, yeasts, and bacteria. Due to their great metabolic versatility, bacteria are the most traditional and well-known microbial surfactant producers, being Bacillus and Pseudomonas species their typical representatives. To be successfully applied in industry, surfactants need to maintain stability under the harsh environmental conditions present in manufacturing processes; thus, the prospection of biosurfactants derived from extremophiles is a promising strategy to the discovery of novel and useful molecules. Bacterial surfactants show interesting properties suitable for a range of applications in the oil industry, food, agriculture, pharmaceuticals, cosmetics, bioremediation, and more recently, nanotechnology. In addition, they can be synthesized using renewable resources as substrates, contributing to the circular economy and sustainability. The article presents a general and updated review of bacterial-derived biosurfactants, focusing on the potential of some groups that are still underexploited, as well as, recent trends and contributions of these versatile biomolecules to circular bioeconomy and nanotechnology.

Enhancement effect of defoamer additives on photo-fermentation biohydrogen production process

Foaming is a key issue should be solved in the process of photo-fermentation biohydrogen production (PFHP), since it has negative influence on the hydrogen yield potential, especially when taken straw as substrate. Appropriate foam control measures must be considered for industrialization. Hence, in this work, foam height and biohydrogen yield were selected as index, the effect of defoamer addition on PFHP was investigated. The defoamer has no negative effect on bacterial growth. In the addition range of 0-1 mL/L, the higher addition amount, indicates better foam control effect. The maximum foam height could be reduced by 55% and the foam existence time by 36 h. The reduction of foam was beneficial to biohydrogen production, and the highest cumulative hydrogen yield was increased 23% at the addition level of 0.125 mL/L.

Controlling the Formation of Foams in Broth to Promote the Co-Production of Microbial Oil and Exopolysaccharide in Fed-Batch Fermentation

A large amount of foam is generated in the production of microbial oil and exopolysaccharide (EPS) by Sporidiobolus pararoseus JD-2, which causes low efficiency in fermentation. In this study, we aimed to reduce the negative effects of foams on the co-production of oil and EPS by controlling the formation of foams in broth. As we have found, the formation of foams is positively associated with cell growth state, air entrapment, and properties of broth. The efficient foam-control method of adding 0.03% (v/v) of the emulsified polyoxyethylene polyoxypropylene pentaerythritol ether (PPE) and feeding corn steep liquor (CSL) at 8–24 h with speed of 0.02 L/h considerably improved the fermentation performance of S. pararoseus JD-2, and significantly increased the oil and EPS concentrations by 8.7% and 12.9%, respectively. The biomass, oil, and EPS concentrations were further increased using a foam backflow device combined with adding 0.03% (v/v) of the emulsified PPE and feeding CSL at 8–24 h, which reached to 62.3 ± 1.8 g/L, 31.2 ± 0.8 g/L, and 10.9 ± 0.4 g/L, respectively. The effective strategy for controlling the formation of foams in fermentation broth reported here could be used as a technical reference for producing frothing products in fed-batch fermentation.

Evaluation of the Antimicrobial Efficacy of N-Acetyl-l-Cysteine, Rhamnolipids, and Usnic Acid-Novel Approaches to Fight Food-Borne Pathogens

In the food industry, the increasing antimicrobial resistance of food-borne pathogens to conventional sanitizers poses the risk of food contamination and a decrease in product quality and safety. Therefore, we explored alternative antimicrobials N-Acetyl-l-cysteine (NAC), rhamnolipids (RLs), and usnic acid (UA) as a novel approach to prevent biofilm formation and reduce existing biofilms formed by important food-borne pathogens (three strains of Salmonella enterica and two strains of Escherichia coli, Listeria monocytogenes, Staphylococcus aureus). Their effectiveness was evaluated by determining minimum inhibitory concentrations needed for inhibition of bacterial growth, biofilm formation, metabolic activity, and biofilm reduction. Transmission electron microscopy and confocal scanning laser microscopy followed by image analysis were used to visualize and quantify the impact of tested substances on both planktonic and biofilm-associated cells. The in vitro cytotoxicity of the substances was determined as a half-maximal inhibitory concentration in five different cell lines. The results indicate relatively low cytotoxic effects of NAC in comparison to RLs and UA. In addition, NAC inhibited bacterial growth for all strains, while RLs showed overall lower inhibition and UA inhibited only the growth of Gram-positive bacteria. Even though tested substances did not remove the biofilms, NAC represents a promising tool in biofilm prevention.

Multi-Scale Biosurfactant Production by Bacillus subtilis Using Tuna Fish Waste as Substrate

As one of the most effective biosurfactants reported to date, lipopeptides exhibit attractive surface and biological activities and have the great potential to serve as biocatalysts. Low yield, high cost of production, and purification hinder the large-scale applications of lipopeptides. Utilization of waste materials as low-cost substrates for the growth of biosurfactant producers has emerged as a feasible solution for economical biosurfactant production. In this study, fish peptone was generated through enzyme hydrolyzation of smashed tuna (Katsuwonus pelamis). Biosurfactant (mainly surfactin) production by Bacillus subtilis ATCC 21332 was further evaluated and optimized using the generated fish peptone as a comprehensive substrate. The optimized production conduction was continuously assessed in a 7 L batch-scale and 100 L pilot-scale fermenter, exploring the possibility for a large-scale surfactin production. The results showed that Bacillus subtilis ATCC 21332 could effectively use the fish waste peptones for surfactin production. The highest surfactin productivity achieved in the pilot-scale experiments was 274 mg/L. The experimental results shed light on the further production of surfactins at scales using fish wastes as an economical substrate.

Uncoupling Foam Fractionation and Foam Adsorption for Enhanced Biosurfactant Synthesis and Recovery

The production of biosurfactants is often hampered by excessive foaming in the bioreactor, impacting system scale-up and downstream processing. Foam fractionation was proposed to tackle this challenge by combining in situ product removal with a pre-purification step. In previous studies, foam fractionation was coupled to bioreactor operation, hence it was operated at suboptimal parameters. Here, we use an external fractionation column to decouple biosurfactant production from foam fractionation, enabling continuous surfactant separation, which is especially suited for system scale-up. As a subsequent product recovery step, continuous foam adsorption was integrated into the process. The configuration is evaluated for rhamnolipid (RL) or 3-(3-hydroxyalkanoyloxy)alkanoic acid (HAA, i.e., RL precursor) production by recombinant non-pathogenic Pseudomonas putida KT2440. Surfactant concentrations of 7.5 g_RL/L and 2.0 g_HAA/L were obtained in the fractionated foam. 4.7 g RLs and 2.8 g HAAs could be separated in the 2-stage recovery process within 36 h from a 2 L culture volume. With a culture volume scale-up to 9 L, 16 g RLs were adsorbed, and the space-time yield (STY) increased by 31% to 0.21 gRL/L·h. We demonstrate a well-performing process design for biosurfactant production and recovery as a contribution to a vital bioeconomy.

Effect of sodium dodecyl sulfate on the production of L-isoleucine by the fermentation of Corynebacterium glutamicum

Corynebacterium glutamicum is a safe and popular industrial microorganism that it is gram-positive bacteria with thick cell walls, which hinder the extracellular secretion of products. Surfactant has good surface or interface activity and can destroy the cell membrane of microorganisms. In this study, the surfactant SDS was used to artificially destroy the cell membrane of Corynebacterium glutamicum, increase the permeability of the cell membrane, and increase the ability of the strain to secrete L-isoleucine. This is the first time that surfactants have been applied to the fermentation of Corynebacterium glutamicum. Results indicated that after optimization, the output of L-isoleucine reached 43.67 g/L, which was 13.01% higher than that without sodium dodecyl sulfate. The yield of the by-products, such as valine, leucine, and alanine, was reduced by 72.30%, 64.30%, 71.70%, respectively. This method can promote the production of L-isoleucine while minimizing the damage of SDS to the strain.