Design Aspects of Solid State Fermentation as Applied to Microbial Bioprocessing

Versatile Applications of Brewer's Spent Grain: Solid-State Fermentation and Nutritional Added Value

Brewer's spent grain (BSG) is a major by-product in the beer-brewing process which contributes to 85% of the entire generated by-product in the brewing process. BSG is rich in proteins, and most of the malt proteins (74-78%) remain insoluble in BSG after the mashing process. Solid-state fermentation (SSF) is a promising bioprocess that enables microorganisms to survive in environments with minimal water and has shown to enhance the nutritional composition of BSG. In this review, the potential application of protein, amino acids (proline, threonine, and serine), phenolic contents, and soluble sugars (glucose, fructose, xylose, arabinose, and cellobiose) extracted from BSG by various microorganisms using SSF is explored. Incorporation of BSG into animal feed, human diets, and as a substrate for microorganisms are the prospects that could be implemented in the industrial scale. This review also discussed various advances to improve the fermentation yield such as symbiotic fermentation, the addition of nitrogen supplements, and an optimal mixture of the agro-industrial waste substrate. Future perspectives on SSF are also addressed to provide important ideas for immediate and future studies. However, challenges include optimizing SSF conditions and design of bioreactors, and operational costs must be addressed in the future to overcome current obstacles. Overall, this mini review highlights the potential benefits of BSG utilization and SSF in a sustainable way.

Simple one-step treatment for saccharification of mango peels using an optimized enzyme cocktail of Aspergillus niger ATCC 9642

Developing efficient microbiological methods to convert polysaccharide-rich materials into fermentable sugars, particularly monosaccharides, is vital for advancing the bioeconomy and producing renewable chemicals and energy sources. This study focused on optimizing the production conditions of an enzyme cocktail from Aspergillus niger ATCC 9642 using solid-state fermentation (SSF) and assessing its effectiveness in saccharifying mango peels through a simple, rapid, and efficient one-step process. A rotatable central composite design was employed to determine optimal conditions of moisture, time, and pH for enzyme production in SSF medium. The optimized enzyme cocktail exhibited cellulase activity (CMCase) at 6.28 U/g, filter paper activity (FPase) at 3.29 U/g, and pectinase activity at 117.02 U/g. These optimal activities were achieved with an SSF duration of 81 h, pH of 4.66, and a moisture content of 59%. The optimized enzyme cocktail effectively saccharified the mango peels without the need for chemical agents. The maximum saccharification yield reached approximately 81%, indicating efficient conversion of mango peels into sugars. The enzyme cocktail displayed consistent thermal stability within the tested temperature range of 30-60°C. Notably, the highest sugar release occurred within 36 h, with glucose, arabinose, galactose, and xylose being the primary monosaccharides released during saccharification. This study highlights the potential application of Aspergillus niger ATCC 9642 and SSF for enzymatic production, offering a simple and high-performance process for monosaccharide production. The optimized enzyme cocktail obtained through solid-state fermentation demonstrated efficient saccharification of mango peels, suggesting its suitability for industrial-scale applications.

Performance of Metarhizium rileyi Nm017: nutritional supplementation to improve production and quality conidia

This study aimed to analyze the effect of nutritional supplements on improving conidia production of Metarhizium rileyi Nm017 at laboratory scale (yields of conidia/substrate and biomass/substrate, and substrate consumption). Also, the influence on quality parameters were evaluated (germination at 36 and 48 h, enzymatic activity, and insecticidal activity on Helicoverpa zea). Six treatments (T1-T6) were assessed and all of them reached maximum conidia concentration after 7 days fermentation, a feasible production timetable. Yields from treatment T6 (yeast extract + V8 juice) were 1.5-threefold higher than the other treatments. Conidia from T6 reached germinations of 56% and 12% at 36 and 48 h, respectively, higher than T1 (without supplements), which had the lowest values found. M. rileyi conidia obtained from treatment T6 had the highest enzymatic activity (0.45 U chitinase g-1, 0.28 U lipase g-1, and 1.29 U protease g-1). However, treatments with the highest conidia yields and enzymatic activity were not positively correlated to the efficacy against H. zea. When M. rileyi was produced on T5 (yeast hydrolysate + V8 juice), conidia were 35% more virulent than treatment T6. The findings evidenced the noticeable impact of nutritional substrate amended for conidia production and quality. This work showed the relevance of insecticidal activity assessment as a selection criterion in the mass production development of a biocontrol agent.

Fungus-based bioherbicides on circular economy

This review aimed to show that bioherbicides are possible in organic agriculture as natural compounds from fungi and metabolites produced by them. It is discussed that new formulations must be developed to improve field stability and enable the commercialization of microbial herbicides. Due to these bottlenecks, it is crucial to advance the bioprocesses behind the formulation and fermentation of bio-based herbicides, scaling up, strategies for field application, and the potential of bioherbicides in the global market. In this sense, it proposed insights for modern agriculture based on sustainable development and circular economy, precisely the formulation, scale-up, and field application of microbial bioherbicides.

A Review on Opportunities and Limitations of Membrane Bioreactor Configuration in Biofuel Production

Biofuels are a clean and renewable source of energy that has gained more attention in recent years; however, high energy input and processing cost during the production and recovery process restricted its progress. Membrane technology offers a range of energy-saving separation for product recovery and purification in biorefining along with biofuel production processes. Membrane separation techniques in combination with different biological processes increase cell concentration in the bioreactor, reduce product inhibition, decrease chemical consumption, reduce energy requirements, and further increase product concentration and productivity. Certain membrane bioreactors have evolved with the ability to deal with different biological production and separation processes to make them cost-effective, but there are certain limitations. The present review describes the advantages and limitations of membrane bioreactors to produce different biofuels with the ability to simplify upstream and downstream processes in terms of sustainability and economics.

Sustainable production of bioemulsifiers, a critical overview from microorganisms to promising applications

Microbial bioemulsifiers are molecules of amphiphilic nature and high molecular weight that are efficient in emulsifying two immiscible phases such as water and oil. These molecules are less effective in reducing surface tension and are synthesized by bacteria, yeast and filamentous fungi. Unlike synthetic emulsifiers, microbial bioemulsifiers have unique advantages such as biocompatibility, non-toxicity, biodegradability, efficiency at low concentrations and high selectivity under different conditions of pH, temperature and salinity. The adoption of microbial bioemulsifiers as alternatives to their synthetic counterparts has been growing in ongoing research. This article analyzes the production of microbial-based emulsifiers, the raw materials and fermentation processes used, as well as the scale-up and commercial applications of some of these biomolecules. The current trend of incorporating natural compounds into industrial formulations indicates that the search for new bioemulsifiers will continue to increase, with emphasis on performance improvement and economically viable processes.

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.

Innovations and developments in single cell protein: Bibliometric review and patents analysis

Background

Global demand for food products derived from alternative proteins and produced through sustainable technological routes is increasing. Evaluation of research progress, main trends and developments in the field are valuable to identify evolutionary nuances.

Methods

In this study, a bibliometric analysis and search of patents on alternative proteins from fermentation processes was carried out using the Web of Science and Derwent World Patents Index^™ databases, using the keywords and Boolean operators "fermentation" AND "single cell protein" OR "single-cell protein." The dataset was processed and graphics generated using the bibliometric software VOSviewer and OriginPro 8.1.

Results

The analysis performed recovered a total of 360 articles, of which 271 were research articles, 49 literature review articles and 40 publications distributed in different categories, such as reprint, proceedings paper, meeting abstract among others. In addition, 397 patents related to the field were identified, with China being the country with the largest number of publications and patents deposits. While this topic is largely interdisciplinary, the majority of work is in the area of Biotechnology Applied Microbiology, which boasts the largest number of publications. The area with the most patent filings is the food sector, with particular emphasis on the fields of biochemistry, beverages, microbiology, enzymology and genetic engineering. Among these patents, 110 are active, with industries or companies being the largest depositors. Keyword analysis revealed that the area of study involving single cell protein has included investigation into types of microorganisms, fermentation, and substrates (showing a strong trend in the use of agro-industrial by-products) as well as optimization of production processes.

Conclusion

This bibliometric analysis provided important information, challenges, and trends on this relevant subject.

Biosynthetic novelty index reveals the metabolic potential of rare actinobacteria isolated from highly oligotrophic sediments

Calculations predict that testing of 5 000-10 000 molecules and >1 billion US dollars (£0.8 billion, £1=$1.2) are required for one single drug to come to the market. A solution to this problem is to establish more efficient protocols that reduce the high rate of re-isolation and continuous rediscovery of natural products during early stages of the drug development process. The study of 'rare actinobacteria' has emerged as a possible approach for increasing the discovery rate of drug leads from natural sources. Here, we define a simple genomic metric, defined as biosynthetic novelty index (BiNI), that can be used to rapidly rank strains according to the novelty of the subset of encoding biosynthetic clusters. By comparing a subset of high-quality genomes from strains of different taxonomic and ecological backgrounds, we used the BiNI score to support the notion that rare actinobacteria encode more biosynthetic gene cluster (BGC) novelty. In addition, we present the isolation and genomic characterization, focused on specialized metabolites and phenotypic screening, of two isolates belonging to genera Lentzea and Actinokineospora from a highly oligotrophic environment. Our results show that both strains harbour a unique subset of BGCs compared to other members of the genera Lentzea and Actinokineospora. These BGCs are responsible for potent antimicrobial and cytotoxic bioactivity. The experimental data and analysis presented in this study contribute to the knowledge of genome mining analysis in rare actinobacteria and, most importantly, can serve to direct sampling efforts to accelerate early stages of the drug discovery pipeline.

Laccase Production of Newly Isolated Trametes versicolor under Batch, Repeated-Batch, and Solid-State Fermentation Processes

In this study, the laccase production ability of the newly isolated Trametes versicolor strain was investigated in three different fermentation processes. In all three fermentation processes, the fungus was able to produce the laccase enzyme. During the solid-state fermentation process 13.21 U/mL laccase activity was detected on the 20th day in the 10 mM copper-containing medium, while this value reached to 27.30 U/mL in the medium containing 0.5 mM ABTS+10 mM copper. During the liquid batch fermentation process, laccase activity was significantly induced in the medium containing 1 mM copper and the laccase activities reached 2.25, 19.83 and 24.57 U/mL compared to the medium without copper on the 3rd, 6th, and 9th days, respectively. ABTS and xylidine induced the laccase production of this strain at a much lower level than copper. The liquid repeated-batch process also significantly induced the laccase production. While low level of enzyme activities were detected in a copper-free medium, laccase activities were induced in the copper-containing medium and the activity increased from 0.66 U/mL to 9.87 U/mL at the 6th use of the pellets. Copper was detected as an effective inducer for laccase production in all fermentation processes and activity staining after native polyacrylamide gel electrophoresis clearly showed the active laccase bands. The results revealed that this strain is a good laccase producer and the laccase production yield varies depending on the fermentation process, production time, and inducer used.

Application of the solid-state fermentation process and its variations in PHA production: a review

Solid-state fermentation (SSF) is a type of fermentation process with potential to use agro-industrial by-products as a carbon source. Nonetheless, there are few studies evaluating SSF compared to submerged fermentation (SmF) to produce polyhydroxyalkanoates (PHAs). Different methodologies are available associating the two processes. In general, the studies employ a 1st step by SSF to hydrolyze the agro-industrial by-products used as a carbon source, and a 2nd step to produce PHA that can be carried out by SmF or SSF. This paper reviewed and compared the different methodologies described in the literature to assess their potential for use in PHA production. The studies evaluated showed that highest PHA yields (86.2% and 82.3%) were achieved by associating SSF and SmF by Cupriavidus necator. Meanwhile, in methodologies using only SSF, Bacillus produced the highest yields (62% and 56.8%). Since PHA (%) does not necessarily represent a higher production by biomass, the productivity parameter was also compared between studies. We observed that the highest productivity results did not necessarily represent the highest PHA (%). C. necator presented the highest PHA yields associating SSF and SmF, however, is not the most suitable microorganism for PHA production by SSF. Concomitant use of C. necator and Bacillus is suggested for future studies in SSF. Also, it discusses the lack of studies on the association of the two fermentation methodologies, and on the scaling of SSF process for PHA production. In addition to demonstrating the need for standardization of results, for comparison between different methodologies.

Full Exploitation of Peach Palm (Bactris gasipaes Kunth): State of the Art and Perspectives

The peach palm (Bactris gasipaes Kunth) is a palm tree native to the Amazon region, with plantations expanding to the Brazilian Southwest and South regions. This work is a critical review of historical, botanical, social, environmental, and nutritional aspects of edible and nonedible parts of the plant. In Brazil, the importance of the cultivation of B. gasipaes to produce palm heart has grown considerably, due to its advantages in relation to other palm species, such as precocity, rusticity and tillering. The last one is especially important, as it makes the exploitation of peach palm hearts, contrary to what happens with other palm tree species, a non-predatory practice. Of special interest are the recent efforts aiming at the valorization of the fruit as a source of carotenoids and starch. Further developments indicate that the B. gasipaes lignocellulosic wastes hold great potential for being upcycled into valuable biotechnological products such as prebiotics, enzymes, cellulose nanofibrils and high fiber flours. Clean technologies are protagonists of the recovery processes, ensuring the closure of the product's life cycle in a "green" way. Future research should focus on expanding and making the recovery processes economically viable, which would be of great importance for stimulating the peach palm production chain.

Bioprocessing of Two Crop Residues for Animal Feeding into a High-Yield Lovastatin Feed Supplement

Simple Summary

Lovastatin is a fungal secondary metabolite that can mitigate rumen methane production. This work aimed at evaluating the lovastatin production by solid-state fermentation from selected crop residues and A. terreus strains, considering the post-fermented residues as feed supplements for ruminants. Fermented oat straw by A. terreus CDBB H-194 exhibited the highest lovastatin yield (23.8 mg/g DM fed). GC–MS analysis identified only a couple of compounds from the residues fermented by CDBB H-194 (1,3-dipalmitin trimethylsilyl ether in the fermented oat straw) and stearic acid hydrazide in the fermented wheat bran) that could negatively affect ruminal bacteria and fungi.

Abstract

This work aimed to evaluate the lovastatin (Lv) production by solid-state fermentation (SSF) from selected crop residues, considering the post-fermented residues as feed supplements for ruminants. The SSF was performed with two substrates (wheat bran and oat straw) and two A. terreus strains (CDBB H-194 and CDBB H-1976). The Lv yield, proximate analysis, and organic compounds by GC–MS in the post-fermented residues were assessed. The combination of the CDBB H-194 strain with oat straw at 16 d of incubation time showed the highest Lv yield (23.8 mg/g DM fed) and the corresponding degradation efficiency of hemicellulose + cellulose was low to moderate (24.1%). The other three treatments showed final Lv concentrations in decreasing order of 9.1, 6.8, and 5.67 mg/g DM fed for the oat straw + CDBB H-1976, wheat bran + CDBB H-194, and wheat bran + CDBB H-1976, respectively. An analysis of variance of the 2² factorial experiment of Lv showed a strong significant interaction between the strain and substrate factors. The kinetic of Lv production adequately fitted a zero-order model in the four treatments. GC–MS analysis identified only a couple of compounds from the residues fermented by A. terreus CDBB H-194 (1,3-dipalmitin trimethylsilyl ether in the fermented oat straw and stearic acid hydrazide in the fermented wheat bran) that could negatively affect ruminal bacteria and fungi. Solid-state fermentation of oat straw with CDBB H-194 deserves further investigation due to its high yield of Lv; low dietary proportions of this post-fermented oat straw could be used as an Lv-carrier supplement for rumen methane mitigation.

Media Optimization by Response Surface Methodology for the Enhanced Production of Acidic Extracellular Pectinase by the Indigenously Isolated Novel Strain Aspergillus cervinus ARS2 Using Solid-State Fermentation

Pectinolytic enzymes are related enzymes that hydrolyze pectic substances. Pectinolytic enzymes are of great interest in industrial applications for softening fruits, extracting and clarifying juices, extracting olive oil, retting textile fibers, preparing gel, and isolating protoplasts. The current work presents acidic extracellular pectinase production using low-cost agro-industrial waste with the indigenously isolated novel strain Aspergillus cervinus. Two fungal isolates, ARS2 and ARS8, with maximum pectinase activity, 41.88 ± 1.57 IU/mL and 39.27 ± 1.14 IU/mL, respectively, were screened out of 27 isolates from decayed fruit peels (orange, banana, and lemon) and soil containing decomposed vegetables. The isolate ARS2, identified as Aspergillus cervinus by molecular characterization, showed the highest pectinase activity of 43.05 ± 1.38IU/mL during screening and was further used for media component screening and optimization studies. To understand their effect on pectinase activity, one-factor-at-a-time (OFAT) studies were conducted on carbon sources, nitrogen sources, and mineral salts. The OFAT results showed the highest pectinase activity for orange peel (carbon source) at 44.51 ± 1.33 IU/mL, peptone (nitrogen source) at 45.05 ± 1.04 IU/mL, and NaH2PO4 (mineral salts) at 43.21 ± 1.12 IU/mL. The most significant media components screened by the Plackett–Burman (PB) design based on the p-value, Pareto chart, and main effect plot, were orange peel (p < 0.001), peptone (p < 0.001), NaH2PO4 (p < 0.001), and KH2PO4 (p < 0.001), which were further optimized using Response Surface Methodology (RSM) and Central Composite Design (CCD). The optimization results for the media components showed a maximum pectinase activity of 105.65 ± 0.31 IU/mL for 10.63 g orange peel, 3.96 g/L peptone, 2.07 g/L KH2PO4, and 2.10 g/L NaH2PO4. Thus, it was discovered that the indigenously isolated novel strain Aspergillus cervinus ARS2 was able to successfully produce a significant amount of pectinase using agro-industrial waste. Therefore, it can be considered for the large-scale optimized production of pectinase to meet industrial demands.

Valorization of Brewer’s Spent Grain Using Biological Treatments and its Application in Feeds for European Seabass (Dicentrarchus labrax)

Brewer’s spent grain (BSG) is the main brewery industry by-product, with potential applications in the feed and food industries due to its carbohydrate composition. In addition, the lignocellulosic nature of BSG makes it an adequate substrate for carbohydrases production. In this work, solid-state fermentation (SSF) of BSG was performed with Aspergillus ibericus, a non-mycotoxin producer fungus with a high capacity to hydrolyze the lignocellulosic matrix of the agro-industrial by-products. SSF was performed at different scales to produce a crude extract rich in cellulase and xylanase. The potential of the crude extract was tested in two different applications: -(1) - the enzymatic hydrolysis of the fermented BSG and (2) - as a supplement in aquafeeds. SSF of BSG increased the protein content from 25% to 29% (w/w), while the fiber content was reduced to 43%, and cellulose and hemicellulose contents were markedly reduced to around 15%. The scale-up of SSF from 10 g of dry BSG in flasks to 50 g or 400 g in tray-type bioreactors increased 55% and 25% production of cellulase and xylanase, up to 323 and 1073 U g⁻¹ BSG, respectively. The optimum temperature and pH of maximal activities were found to be 55°C and pH 4.4 for xylanase and 50°C and pH 3.9 for cellulase, cellulase being more thermostable than xylanase when exposed at temperatures from 45°C to 60°C. A Box–Behnken factorial design was applied to optimize the hydrolysis of the fermented BSG by crude extract. The crude extract load was a significant factor in sugars release, highlighting the role of hydrolytic enzymes, while the load of fermented BSG, and addition of a commercial β-glucosidase were responsible for the highest phenolic compounds and antioxidant activity release. The lyophilized crude extract (12,400 and 1050 U g⁻¹ lyophilized extract of xylanase and cellulase, respectively) was also tested as an enzyme supplement in aquafeed for European seabass (Dicentrarchus labrax) juveniles. The dietary supplementation with the crude extract significantly improved feed and protein utilization. The processing of BSG using biological treatments, such as SSF with A. ibericus, led to the production of a nutritionally enriched BSG and a crude extract with highly efficient carbohydrases capable of hydrolyzing lignocellulosic substrates, such as BSG, and with the potential to be used as feed enzymes with remarkable results in improving feed utilization of an important aquaculture fish species.

Lignocellulosic substrates as starting materials for the production of bioactive biopigments

The search for sustainable processes is constantly increasing in the last years, so reusing, recycling and adding value to residues and by-products from agroindustry is a consolidated area of research. Particularly in the field of fermentation technology, the lignocellulosic substrates have been used to produce a diversity of chemicals, fuels and food additives. These residues or by-products are rich sources of carbon, which may be used to yield fermentescible sugars upon hydrolysis, but are usually inaccessible to enzyme and microbial attack. Therefore, pre-treatments (e.g. hydrolysis, steam explosion, biological pretreatment or others) are required prior to microbial action. Biopigments are added-value compounds that can be produced biotechnologically, including fermentation processes employing lignocellulosic substrates. These molecules are important not only for their coloring properties, but also for their biological activities. Therefore, this paper discusses the most recent and relevant processes for biopigment production using lignocellulosic substrates (solid-state fermentation) or their hydrolysates.

Phytotoxicity Optimization of Fungal Metabolites Produced by Solid and Submerged Fermentation and its Ecotoxicological Effects

Research and commercial production of bioherbicides occur to a lesser extent compared to bioinsecticides and biofungicides. In order to contribute to developing new bioherbicides with low environmental impact, this study aimed to increase the phytotoxicity of metabolites of the fungus Mycoleptodiscus indicus UFSM 54 by optimizing solid and submerged fermentation and evaluate the ecotoxicological effects on earthworms (Eisenia andrei). The Plackett-Burman and central composite rotatable designs were used to optimize metabolite phytotoxicity. The variables optimized in the fermentation were temperature, agitation, pH, water volume in the culture medium, glucose concentration, and yeast extract. The fungus was grown on sugarcane bagasse substrate, and its metabolites were applied to detached Cucumis sativus, Conyza sp., and Sorghum bicolor leaves and used in an avoidance test and acute exposure to earthworms. Metabolite phytotoxicity in submerged fermentation was optimized at 35 °C, 50 rpm, and 1.5 g l^-1 of glucose and in solid fermentation at 30-37 °C and in 14-32 ml of water. The metabolites severely damaged germination, initial growth, and leaves of the three plants, and at the doses tested (maximum of 113.92 ml kg^-1), the metabolites of M. indicus UFSM 54 were not toxic to earthworms.

Production of Lignocellulolytic Enzymes and Phenolic Compounds by Lentinus strigosus from the Amazon Using Solid-State Fermentation (SSF) of Guarana (Paullinia cupana) Residue

The Amazon rainforest has a rich biodiversity, and studies of Basidiomycete fungi that have biomolecules of biotechnological interest are relevant. The use of lignocellulosic biomass in biotechnological processes proposes an alternative use, and also adds value to the material when employed in the bioconversion of agro-industrial waste. In this context, this study evaluate the production of lignocellulolytic enzymes (carboxymethylcellulases (CMCase), xylanase, pectinase, laccase) as well as phenolic compounds and proteases by solid-state fermentation (SSF) using the fungus Lentinus strigosus isolated from Amazon. The guarana (Paullinia cupana) residue was characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared spectroscopy (FTIR). SSF was carried out with 60% humidification of the residue, at 30 °C, for 10 days. The lignocellulosic biomass presented fragmented structures with irregular shapes and porosities, and was mainly constituted by cellulose (19.16%), hemicellulose (32.83%), and lignin (6.06%). During the SSF, significant values of CMCase (0.84 U/g) on the 8th day, xylanase (1.00 U/g) on the 7th day, pectinase (2.19 U/g) on the 6th day, laccase (176.23 U/mL) on the 5th day, phenolic compounds (10.27 μg/mL) on the 1st day, soluble proteins (0.08 mg/mL) on the 5th day, and protease (8.30 U/mL) on the 6th day were observed. In general, the agro-industrial residue used provided promising results as a viable alternative for use as a substrate in biotechnological processes.

A Temporal Evolution Perspective of Lipase Production by Yarrowia lipolytica in Solid-State Fermentation

Lipases are enzymes that, in aqueous or non-aqueous media, act on water-insoluble substrates, mainly catalyzing reactions on carboxyl ester bonds, such as hydrolysis, aminolysis, and (trans)esterification. Yarrowia lipolytica is a non-conventional yeast known for secreting lipases and other bioproducts; therefore, it is of great interest in various industrial fields. The production of lipases can be carried on solid-state fermentation (SSF) that utilizes solid substrates in the absence, or near absence, of free water and presents minimal problems with microbial contamination due to the low water contents in the medium. Moreover, SSF offers high volumetric productivity, targets concentrated compounds, high substrate concentration tolerance, and has less wastewater generation. In this sense, the present work provides a temporal evolution perspective regarding the main aspects of lipase production in SSF by Y. lipolytica, focusing on the most relevant aspects and presenting the potential of such an approach.

Biological Approaches for Extraction of Bioactive Compounds From Agro-industrial By-products: A Review

Bioactive compounds can provide health benefits beyond the nutritional value and are originally present or added to food matrices. However, because they are part of the food matrices, most bioactive compounds remain in agroindustrial by-products. Agro-industrial by-products are generated in large quantities throughout the food production chain and can—when not properly treated—affect the environment, the profit, and the proper and nutritional distribution of food to people. Thus, it is important to adopt processes that increase the use of these agroindustrial by-products, including biological approaches, which can enhance the extraction and obtention of bioactive compounds, which enables their application in food and pharmaceutical industries. Biological processes have several advantages compared to nonbiological processes, including the provision of extracts with high quality and bioactivity, as well as extracts that present low toxicity and environmental impact. Among biological approaches, extraction from enzymes and fermentation stand out as tools for obtaining bioactive compounds from various agro-industrial wastes. In this sense, this article provides an overview of the main bioactive components found in agroindustrial by-products and the biological strategies for their extraction. We also provide information to enhance the use of these bioactive compounds, especially for the food and pharmaceutical industries.

Impact of solid-state fermentation on factors and mechanisms influencing the bioactive compounds of grains and processing by-products

Cereal and legume grains and their processing by-products are rich sources of bioactives such as phenolics with considerable health potential, but these bioactives suffer from low bioaccessibility and bioavailability, resulting in limited use. Several studies have demonstrated that solid-state fermentation (SSF) with food-grade microorganisms is effective in releasing bound phenolic compounds in cereal and legume products. In this review, we discuss the effect of SSF on cereal and legume grains and their by-products by examining the role of specific microorganisms, their hydrolytic enzymes, fermentability of agri-food substrates, and the potential health benefits of SSF-enhanced bioactive compounds. SSF with fungi (Aspergillus spp. and Rhizopus spp.), bacteria (Bacillus subtilis and lactic acid bacteria (LAB) spp.) and yeast (Saccharomyces cerevisiae) significantly increased the bioactive phenolics and antioxidant capacities in cereal and legume grains and by-products, mainly through carbohydrate-cleaving enzymes. Increased bioactive phenolic and peptide contents of SSF-bioprocessed cereal and legume grains have been implicated for improved antioxidant, anti-inflammatory, anti-carcinogenic, anti-diabetic, and angiotensin-converting-enzyme (ACE) inhibitory effects in fermented agri-food products, but these remain as preliminary results. Future research should focus on the microbial mechanisms, suitability of substrates, and the physiological health benefits of SSF-treated grains and by-products.

Agro-Industrial Wastes: A Substrate for Multi-Enzymes Production by Cryphonectria parasitica

This study aims to produce a mix of enzymes through Solid State Fermentation (SSF) of raw materials. Four different, easily available, agro-industrial wastes were evaluated as SSF substrates for enzymes production by Cryphonectria parasitica (Murr.) Barr. environmental strains named CpA, CpB2, CpC4, and CpC7. Among the tested wastes, organic wheat bran for human use and wheat bran for animal feed better supports C. parasitica growth and protease production without any supplements. SDS-PAGE analyses highlighted the presence of three bands corresponding to an extracellular laccase (77 kDa), to the endothiapepsin (37 kDa), and to a carboxylesterase (60.6 kDa). Protease, laccase, and esterase activities by C. parasitica in SSF were evaluated for 15 days, showing the maximum protease activity at day 9 (3955.6 AU/gsf,). Conversely, the best laccase and esterase production was achieved after 15 days. The C. parasitica hypovirulent CpC4 strain showed the highest laccase and esterase activity (93.8 AU/gsf and 2.5 U/gsf, respectively). These results suggest the feasibility of a large-scale production of industrially relevant enzymes by C. parasitica strains in SSF process on low value materials.

Morphological growth pattern of Phanerochaete chrysosporium cultivated on different Miscanthus x giganteus biomass fractions

BACKGROUND

Solid-state fermentation is a fungal culture technique used to produce compounds and products of industrial interest. The growth behaviour of filamentous fungi on solid media is challenging to study due to the intermixity of the substrate and the growing organism. Several strategies are available to measure indirectly the fungal biomass during the fermentation such as following the biochemical production of mycelium-specific components or microscopic observation. The microscopic observation of the development of the mycelium, on lignocellulosic substrate, has not been reported. In this study, we set up an experimental protocol based on microscopy and image processing through which we investigated the growth pattern of Phanerochaete chrysosporium on different Miscanthus x giganteus biomass fractions.

RESULTS

Object coalescence, the occupied surface area, and radial expansion of the colony were measured in time. The substrate was sterilized by autoclaving, which could be considered a type of pre-treatment. The fastest growth rate was measured on the unfractionated biomass, followed by the soluble fraction of the biomass, then the residual solid fractions. The growth rate on the different fractions of the substrate was additive, suggesting that both the solid and soluble fractions were used by the fungus. Based on the FTIR analysis, there were differences in composition between the solid and soluble fractions of the substrate, but the main components for growth were always present. We propose using this novel method for measuring the very initial fungal growth by following the variation of the number of objects over time. Once growth is established, the growth can be followed by measurement of the occupied surface by the mycelium.

CONCLUSION

Our data showed that the growth was affected from the very beginning by the nature of the substrate. The most extensive colonization of the surface was observed with the unfractionated substrate containing both soluble and solid components. The methodology was practical and may be applied to investigate the growth of other fungi, including the influence of environmental parameters on the fungal growth.

New and potent production platform of the acetylcholinesterase inhibitor huperzine A by gamma-irradiated Alternaria brassicae under solid-state fermentation

Huperzine-A (HupA) is an emerging, powerful, and promising natural acetylcholinesterase inhibitor. Despite that, the achieved yields of HupA from microbial sources are still far from the industrial applications. Accordingly, this paper was conducted to valorize solid-state fermentation (SSF) as an efficient production platform of HupA. Four agro-industrial wastes, namely rice bran, potato peel, sugarcane bagasse, and wheat bran, were tested and screened as cultural substrates for the production of HupA by the endophytic Alternaria brassica under SSF. Maximum HupA production was attained on using rice bran moistened by Czapex's dox mineral broth. In the effort to increase the HupA titer, supplementation of the best moistening agent by different carbon and nitrogen sources was successfully investigated. Additionally, factors affecting HupA production under SSF including substrate concentration, moistening level, and inoculum concentration were optimized using response surface methodology. A Box-Behnken design was applied for generating a predictive model of the interactions between these factors. Under the optimum conditions of 15 g rice bran, inoculum concentration of 5 × 10⁶ spores mL^-1, and 60% moisture level, HupA concentration was intensified to 518.93 μg g^-1. Besides, HupA production by the fungal strain was further enhanced using gamma-irradiation mutagenesis. The final HupA production was significantly intensified following exposure to 0.5 KGy gamma radiation to 1327 μg g^-1, which represents a 12.85-fold increase. This is the first report on the successful production of the natural fungal metabolite HupA under SSF. Moreover, the achieved yield in this study using agro-industrial wastes may contribute to reducing the cost of HupA manufacture.Key points• Different agro-industrial by-products were tried as cultural substrates for the production of the acetylcholinesterase inhibitor HupA under SSF for the first time.• Factors affecting HupA production under SSF were optimized using response surface methodology.• The final HupA production was intensified following exposure to gamma radiation recording 1327 μg g^-1, which represents a 12.85-fold increase.

Technological tools and strategies for culturing human gut microbiota in engineered in vitro models

The gut microbiota directly impacts the pathophysiology of different human body districts. Consequently, microbiota investigation is an hot topic of research and its in vitro culture has gained extreme interest in different fields. However, the high sensitivity of microbiota to external stimuli, such as sampling procedure, and the physicochemical complexity of the gut environment make its in vitro culture a challenging task. New engineered microfluidic gut-on-a-chip devices have the potential to model some important features of the intestinal structure, but they are usually unable to sustain culture of microbiota over an extended period of time. The integration of gut-on-a-chip devices with bioreactors for continuous bacterial culture would lead to fast advances in the study of microbiota-host crosstalk. In this review, we summarize the main technologies for the continuous culture of microbiota as upstream systems to be coupled with microfluidic devices to study bacteria-host cells communication. The engineering of integrated microfluidic platforms, capable of sustaining both anaerobic and aerobic cultures, would be the starting point to unveil complex biological phenomena proper of the microbiota-host crosstalks, paving to way to multiple research and technological applications.

Characterization of a Biofilm Bioreactor Designed for the Single-Step Production of Aerial Conidia and Oosporein by Beauveria bassiana PQ2

Beauveria bassiana is an entomopathogenic fungus that is used for the biological control of different agricultural pest insects. B. bassiana is traditionally cultivated in submerged fermentation and solid-state fermentation systems to obtain secondary metabolites with antifungal activity and infective spores. This work presents the design and characterization of a new laboratory-scale biofilm bioreactor for the simultaneous production of oosporein and aerial conidia by B. bassiana PQ2. The reactor was built with materials available in a conventional laboratory. K_La was determined at different air flows (1.5–2.5 L/min) by two different methods in the liquid phase and in the exhaust gases. The obtained values showed that an air flow of 2.5 L/min is sufficient to ensure adequate aeration to produce aerial conidia and secondary metabolites by B. bassiana. Under the conditions studied, a concentration of 183 mg oosporein per liter and 1.24 × 10⁹ spores per gram of support was obtained at 168 h of culture. These results indicate that the biofilm bioreactor represents a viable alternative for the production of products for biological control from B. bassiana.

Potential Role of Sequential Solid-State and Submerged-Liquid Fermentations in a Circular Bioeconomy

An efficient processing of organic solid residues will be pivotal in the development of the circular bioeconomy. Due to their composition, such residues comprise a great biochemical conversion potential through fermentations. Generally, the carbohydrates and proteins present in the organic wastes cannot be directly metabolized by microorganisms. Thus, before fermentation, enzymes are used in a hydrolysis step to release digestible sugars and nitrogen. Although enzymes can be efficiently produced from organic solid residues in solid-state fermentations (SsF), challenges in the development and scale-up of SsF technologies, especially bioreactors, have hindered a wider application of such systems. Therefore, most of the commercial enzymes are produced in submerged-liquid fermentations (SmF) from expensive simple sugars. Instead of independently evaluating SsF and SmF, the review covers the option of combining them in a sequential process in which, enzymes are firstly produced in SsF and then used for hydrolysis, yielding a suitable medium for SmF. The article reviews experimental work that has demonstrated the feasibility of the process and underlines the benefits that such combination has. Finally, a discussion is included which highlights that, unlike typically perceived, SsF should not be considered a counterpart of SmF but, in contrast, the main advantages of each type of fermentation are accentuated in a synergistic sequential SsF-SmF.

Bioprocessing of Agricultural Residues as Substrates and Optimal Conditions for Phytase Production of Chestnut Mushroom, Pholiota adiposa, in Solid State Fermentation

Phytase is an enzyme that breaks down phytates to release phosphorus in an available form. This enzyme plays an important role in animals, especially monogastric animals. It serves to improve phytate digestion along with phosphorus absorption, which are required for optimal growth performance and health. In this study, five mushroom species (Amauroderma rugosum SDBR-CMU-A83, Ganoderma mastoporum SDBR-CMU-NK0244, Marusmius sp.1 SDBR-CMU-NK0215, Pholiota adiposa SDBR-CMU-R32 and Piptoporellus triqueter SDBR-CMU-P234) out of 27 mushroom species displayed positive phytase production by agar plate assay. Consequently, these five mushroom species were selected for determination of their potential ability to produce phytase under solid-state fermentation using five agricultural residues (coffee parchment, oil palm empty fruit bunches, rice bran, sawdust, and water hyacinth) as substrates. The highest yield of phytase production (17.02 ± 0.92 units/gram dry substrate) was obtained after one week of fermentation. Optimization for phytase production was determined by statistical approaches using a Plackett-Burman design to screen ten parameters of relevant substrate components. Two significant parameters, the amount of water hyacinth and the moisture content, were found to affect the production process of phytase. Furthermore, the optimal temperature, pH value, and fermentation period were evaluated. The results indicated that the highest degree of phytase production at 53.66 ± 1.68 units/gram dry substrate (3.15-fold increase) was obtained in water hyacinth containing 85% moisture content by addition with a suitable basal liquid medium at a pH value of 6.5 after being incubated at 30 °C for seven days. The crude phytase of P. adiposa was precipitated and the precipitated extract was then used to determine partial characterizations. The precipitated extract displayed high activities after exposure to conditions of 42 °C and pH 5.0. Furthermore, Fe²⁺ enhanced phytase activity and precipitated extract displayed the best stability at a pH value of 8.0 and a temperature of 4 °C.

Improving enzyme production by solid-state cultivation in packed-bed bioreactors by changing bed porosity and airflow distribution

Enzymes production by solid-state cultivation in packed-bed bioreactor needs to be improved by mathematical modeling and also by experimentation. In this work, a mixture of sugarcane bagasse and wheat bran was used for the growth of the fungus Myceliophthora thermophila I-1D3b, able to secrete endoglucanase and xylanase, enzymes of interest in the second-generation ethanol production. Bench and pilot-scale bioreactors were used for the experiments, while critical parameters as bed porosity and airflow distribution were evaluated. Results showed enzymes with higher activities for the most porous medium, even though the less substrate amount to be cultivated. For the pilot-scale bioreactor, only the most porous medium was evaluated using different airflow distribution techniques. Using an inner tube for air supply resulted in more homogeneous enzyme production, with higher activities. The results here presented will be helpful for the scale-up of this class of bioreactor into industrial apparatuses.

Semi-pilot scale production of biodiesel from waste frying oil by genetically improved fungal lipases

This paper addresses the issue of combining the usage of waste frying oil (WFO), as a feedstock, and a lipase produced in solid-state fermentation (SSF), as a biocatalyst, for semi-pilot scale production of biodiesel as fatty acid methyl esters (FAME). Two fungal mutants namely; Rhizopus stolonifer 1aNRC11 mutant F (1F) and Aspergillus tamarii NDA03a mutant G (3G) were used as a cocatalyst. The two mutants were cultivated separately by SSF in a tray bioreactor. The dried fermented solid of 1F and 3G mutants were used in a ratio of 3:1, respectively, for WFO transesterification. Optimization of several semi-pilot process stages including SSF and WFO transesterification reaction conditions resulted in 92.3% conversion of WFO to FAME. This FAME yield was obtained after 48 h using 10% cocatalyst (w/w of WFO), 10% water (w/w of WFO) and 3:1 methanol/ WFO molar ratio at 30 °C and 250 rpm. A preliminary economic evaluation of produced biodiesel price (190 $/Ton) is less than half the price of petroleum diesel in Egypt (401$/Ton) and is about 40.3% the price of biodiesel produced using a pure enzyme, which is a promising result. This strategy makes the biodiesel synthesis process greener, economical and sustainable.

Newly designed multi-stacked circular tray solid-state bioreactor: analysis of a distributed parameter gas balance during solid-state fermentation with influence of variable initial moisture content arrangements

Background

The growth of Aspergillus awamori and Aspergillus oryzae in a self-designed, multi-stacked circular tray solid-state bioreactor (SSB), operating in solid-state fermentation (SSF) conditions at a laboratory scale, was studied. The bioreactor was divided into six layers by six circular perforated trays. Wheat bran was used as both a carrier of bound mycelia and nutrient medium for the growth of A. awamori and A. oryzae. The new tray SSB is equipped with instrumentation (an oxygen (O2)/carbon dioxide (CO2) gas analyser and a thermocouple) to continuously monitor O2 consumption and CO2 and heat evolved, which can directly be used to monitor the fungal biomass. The integrated Gompertz model was used to describe the accumulated evolution of CO2.

Results

The results from the models strongly suggest that the evolved and accumulated CO2 can be used to excellently describe fungal growth. Another important parameter that can be determined by the gas balance method is the respiratory quotient (RQ). This is the ratio of the CO2 evolution rate (CER) to the O2 uptake rate (OUR). The use of CER and OUR confirmed that correlated measurements of microbial activity are available, and the determination of RQ may propose an explanation for differences from expected levels. The kinetic behaviour of the fungal culture, using raw CO2, which represents an accumulation term, was integrated with respect to time and fitted to a Gompertz model, a log-like equation. The model can be used to generate parameter values that may be used to verify the experimental data, and also to simulate and optimise the process.

Conclusion

Overall, A. awamori and A. oryzae have their own ability to degrade and utilise the complex compositions contained in the solid substrate, and fermentation conditions may lead to possible comparisons. In addition, multi-stacked circular tray SSB systems demonstrated an excellent system for further investigations of mass transfer and possibly for large-scale operation, though considerable optimisation work remains to be done; for example, the height/diameter ratio and total number of trays should be optimised.