Cheese Whey Processing: Integrated Biorefinery Concepts and Emerging Food Applications

Comparative study of the oligosaccharide profile in goat, bovine, sheep, and human milk whey

Milk oligosaccharides are high added value compounds that could be obtained by exploiting cheese whey, a byproduct of dairy industry. The objective was to compare the abundance and diversity of oligosaccharides in whey samples from domestic animals and humans. During fresh cheese making, whey samples were collected and analyzed by untargeted and targeted small molecule analysis using high-resolution mass-spectrometry. A great similarity in the metabolite profile between goat and sheep was observed. Up to 11 oligosaccharides were observed in the sheep whey from those typically found in humans. The concentration of 2'-Fucosyllactose (0.136 ± 0.055 g/L) and 3-Fucosyllactose (0.079 ± 0.009 g/L) were significantly higher (p-value <0.01) in sheep whey, while the concentration of 3'-Sialyllactose (0.826 ± 0.638 g/L) was higher in goat whey. No significant differences were observed between goat and sheep whey for the other oligosaccharides (p-value >0.05). Therefore, sheep and goat whey could become an important source of oligosaccharides through their revalorization.

Bio-upcycling of cheese whey: Transforming waste into raw materials for biofuels and animal feed

Cheese whey (CW), by-product of cheese production, has potential as a valuable resource due to its nutritional composition. Although options for CW degradation have been explored, a biological treatment with black soldier fly larvae (BSFL) has not been reported. This study evaluated the growth and composition of BSFL in four experimental diets with CW under different conditions. Results show that the use of CW allows larval development and weight gain, also, the conversion into larval biomass was up to 0.215. Diets ED3 (fresh CW, 38 °C) and ED4 (fresh CW, room temperature) allowed higher weight accumulation (final weight up to 0.285 g); the highest fat accumulation (12 % higher than control) was observed in ED3 (up to 45.57 %), which had less protein. Moreover, higher amounts of saturated fatty acids are generated. This study highlights the importance of an appropriate pretreatment designed for a specific waste to control desired by-products.

Single-Cell Protein and Ethanol Production of a Newly Isolated Kluyveromyces marxianus Strain through Cheese Whey Valorization

The present work examined the production of single-cell protein (SCP) by a newly isolated strain of Kluyveromyces marxianus EXF-5288 under increased lactose concentration of deproteinized cheese whey (DCW) and different temperatures (in °C: 20.0, 25.0, 30.0 and 35.0). To the best of the authors' knowledge, this is the first report examining the ability of Kluyveromyces marxianus species to produce SCP at T = 20.0 °C. Different culture temperatures led to significant differences in the strain's growth, while maximum biomass and SCP production (14.24 ± 0.70 and 6.14 ± 0.66 g/L, respectively) were observed in the cultivation of K. marxianus strain EXF-5288 in shake-flask cultures at T = 20.0 °C. Increased DCW lactose concentrations (35.0-100.0 g/L) led to increased ethanol production (Ethmax = 35.5 ± 0.2 g/L), suggesting that K. marxianus strain EXF-5288 is "Crabtree-positive". Batch-bioreactor trials shifted the strain's metabolism to alcoholic fermentation, favoring ethanol production. Surprisingly, K. marxianus strain EXF-5288 was able to catabolize the produced ethanol under limited carbon presence in the medium. The dominant amino acids in SCP were glutamate (15.5 mg/g), aspartic acid (12.0 mg/g) and valine (9.5 mg/g), representing a balanced nutritional profile.

Recent advancements in development and application of microbial cellulose in food and non-food systems

Microbial cellulose is a fermented form of very pure cellulose with a fibrous structure. The media rich in glucose or other carbon sources are fermented by bacteria to produce microbial cellulose. The bacteria use the carbon to produce cellulose, which grows as a dense, gel-like mat on the surface of the medium. The product was then collected, cleaned, and reused in various ways. The properties of microbial cellulose, such as water holding capacity, gas permeability, and ability to form a flexible, transparent film make it intriguing for food applications. Non-digestible microbial cellulose has been shown to improve digestive health and may have further advantages. It is also very absorbent, making it a great option for use in wound dressings. The review discusses the generation of microbial cellulose and several potential applications of microbial cellulose in fields including pharmacy, biology, materials research, and the food industry.

Glycomacropeptide: A comprehensive understanding of its major biological characteristics and purification methodologies

Glycomacropeptide (GMP) is a bioactive peptide derived from whey protein, consisting of 64 amino acids. It is a phenylalanine-free peptide, making it a beneficial dietary option for individuals dealing with phenylketonuria (PKU). PKU is an inherited metabolic disorder characterized by high levels of phenylalanine in the bloodstream, resulting from a deficiency of phenylalanine dehydrogenase in affected individuals. Consequently, patients with PKU require lifelong adherence to a low-phenylalanine diet, wherein a significant portion of their protein intake is typically sourced from a phenylalanine-free amino acid formula. GMP has several nutritional values, numerous bioactivity properties, and therapeutic effects in various inflammatory disorders. Despite all these features, the purification of GMP is an imperative requirement; however, there are no unique methods for achieving this goal. Traditionally, several methods have been used for GMP purification, such as thermal or acid treatment, alcoholic precipitation, ultrafiltration (UF), gel filtration, and membrane separation techniques. However, these methods have poor specificity, and the presence of large amounts of impurities can interfere with the analysis of GMP. More efficient and highly specific GMP purification methods need to be developed. In this review, we have highlighted and summarized the current research progress on the major biological features and purification methodologies associated with GMP, as well as providing an extensive overview of the recent developments in using charged UF membranes for GMP purification and the influential factors.

Emerging Trends in Bioavailability and Pharma-Nutraceutical Potential of Whey Bioactives

Whey, a component of milk and a useful by-product of the dairy industry's casein and cheese-making, has been used for generations to augment animal feed. It contains a range of proteins, including α-lactalbumin, β-lactoglobulin, bovine serum albumin, heavy and light chain immunoglobulins, lactoferrin, glycomacropeptide, and lactoperoxidase. Whey proteins exhibit great potential as biopolymers for creating bioactive delivery systems owing to their distinct health-enhancing characteristics and the presence of numerous amino acid groups within their structures. Whey has considerable factors such as antitumor, anti-inflammatory, antihypertensive, hypolipidemic, antiviral, and antibacterial properties in addition to chelating. The global market of whey protein stood at USD 5.33 billion in 2021, with a projected compound annual growth rate of 10.48% spanning the interval from 2022 to 2030. The escalating demand for whey protein is intrinsically linked to the amplifying consciousness surrounding healthy lifestyles. Notably, protein supplements are recurrently endorsed by fitness and sports establishments, thereby accentuating the focal point of customers toward whey protein. This review focuses on nutritional composition, whey bioactives, and their bioavailability with potential health benefits.

Evaluation of Cellular Responses by Chlamydomonas reinhardtii in Media Containing Dairy-Processing Residues Derived from Cheese as Nutrients by Analyzing Cell Growth Activity and Comprehensive Gene Transcription Levels

Utilities of whey powder (WP) and whey protein concentrate 34% powder (WPC34) prepared as dairy-processing residues were evaluated using a green alga Chlamydomonas reinhardtii. Analysis of C. reinhardtii growth showed that the strain used WP and WPC34 as nitrogen sources. Its specific growth rate and maximum cell density in WP-containing medium were higher than those in WPC34-containing medium; growth with WPC34 was improved by adding KCl or K2HPO4, which content was decreased as a result of WPC34's preparation from WP. Although the lipid contents in media containing dairy-processing residues were 2.72 ± 0.31 wt% and 2.62 ± 0.20 wt% with no significant difference, the composition ratio of fatty acid C14 with WPC34 was higher than that with WP and the composition ratio of the sum of fatty acid-C16 and -C18 with WPC34 tended to be lower than that with WP. Additionally, analyses of gene transcription showed that the transcription level of acetyl-CoA carboxylase biotin carboxyl carrier protein in WPC34-containing medium was lower than that in WP-containing medium, possibly affecting the ratios of the chain lengths of fatty acids. The transcription of genes involved in glycolysis and the TCA cycle was outstandingly lower in algae grown in WPC34-containing medium when compared to those cultivated in the presence of WP, resulting in differences in energy production for cell proliferation.

Innovative applications of whey protein for sustainable dairy industry: Environmental and technological perspectives-A comprehensive review

Industrial waste management is critical to maintaining environmental sustainability. The dairy industry (DI), as one of the major consumers of freshwater, generates substantial whey dairy effluent, which is notably rich in organic matter and thus a significant pollutant. The effluent represents environmental risks due to its high biological and chemical oxygen demands. Today, stringent government regulations, environmental laws, and heightened consumer health awareness are compelling industries to responsibly manage and reuse whey waste. Therefore, this study investigates sustainable solutions for efficiently utilizing DI waste. Employing a systematic review approach, the research reveals that innovative technologies enable the creation of renewable, high-quality, value-added food products from dairy byproducts. These innovations offer promising sustainable waste management strategies for the dairy sector, aligning with economic interests. The main objectives of the study deal with, (a) assessing the environmental impact of dairy sector waste, (b) exploring the multifaceted nutritional and health benefits inherent in cheese whey, and (c) investigating diverse biotechnological approaches to fashion value-added, eco-friendly dairy whey-based products for potential integration into various food products, and thus fostering economic sustainability. Finally, the implications of this work span theoretical considerations, practical applications, and outline future research pathways crucial for advancing the sustainable management of dairy waste.

Unlocking the potential of biosurfactants: Production, applications, market challenges, and opportunities for agro-industrial waste valorization

Biosurfactants are eco-friendly compounds with unique properties and promising potential as sustainable alternatives to chemical surfactants. The current review explores the multifaceted nature of biosurfactant production and applications, highlighting key fermentative parameters and microorganisms able to convert carbon-containing sources into biosurfactants. A spotlight is given on biosurfactants' obstacles in the global market, focusing on production costs and the challenges of large-scale synthesis. Innovative approaches to valorizing agro-industrial waste were discussed, documenting the utilization of lignocellulosic waste, food waste, oily waste, and agro-industrial wastewater in the segment. This strategy strongly contributes to large-scale, cost-effective, and environmentally friendly biosurfactant production, while the recent advances in waste valorization pave the way for a sustainable society.

Factors affecting acid protease production by Mucor circinelloides MG603064.1 through SmF process: characterization and fromage frais making

The exploitation of food industry wastes and their conversion into value-added products present a promising and continuously growing field, given the diversity of elaborated wastes. The current work aimed to utilize sweet cheese whey as a growth medium for acid protease production by a local fungus strain. The biochemical and physicochemical properties of the cheese whey, such as pH, conductivity, chemical oxygen demand, biological oxygen demand (BOD5), total nitrogen and protein contents, and mineral salts, were assessed using various analytical methods. The effect of certain parameters on acid protease production by Mucor circinelloides MG603064.1 through the SmF process was investigated using the conventional design method "One factor at a time". Subsequent to characterization, the crude extract was used in a trial to create fromage frais, compared to the commercial rennin CHY-MAX® Powder Extra. Cheese whey characterization revealed its richness in total nitrogen (1.044 ± 0.044 g/l), protein content (6.52 ± 0.04 g/l), and principal mineral salts: calcium (1.637 ± 0.037 g/l), phosphorus (1.173 ± 0.023 g/l), and chloride (1.66 ± 0.09 g/l). The optimal values of the SmF process for acid protease production, such as the inoculum size, beef extract, and KH2PO4 supplements, the initial pH of cheese whey, and incubation temperature were, respectively, 11% (v/v), 0.4% (w/v), 0.5% (w/v), 5.5, and 30°C. Under these conditions, the lowest milk-clotting time of 290 s was achieved, representing an 18.41-fold increase compared to the initial step using the unoptimized medium. The enzyme showed maximum milk-clotting activity at pH 5, a temperature of 60°C, and in the presence of 0.025 M of CaCl2. The enzyme activity also significantly improved with sonication (35 kHz) for 10 min. The crude extract of M. circinelloides ensured the production of fresh cheese samples with characteristics roughly similar to those obtained by the control (CHY-MAX® rennin). The acid protease of M. circinelloides could successfully substitute the conventional rennin in the manufacture of fresh cheese.

β-Galactosidase: a traditional enzyme given multiple roles through protein engineering

β-Galactosidases are crucial carbohydrate-active enzymes that naturally catalyze the hydrolysis of galactoside bonds in oligo- and disaccharides. These enzymes are commonly used to degrade lactose and produce low-lactose and lactose-free dairy products that are beneficial for lactose-intolerant people. β-galactosidases exhibit transgalactosylation activity, and they have been employed in the synthesis of galactose-containing compounds such as galactooligosaccharides. However, most β-galactosidases have intrinsic limitations, such as low transglycosylation efficiency, significant product inhibition effects, weak thermal stability, and a narrow substrate spectrum, which greatly hinder their applications. Enzyme engineering offers a solution for optimizing their catalytic performance. The study of the enzyme's structure paves the way toward explaining catalytic mechanisms and increasing the efficiency of enzyme engineering. In this review, the structure features of β-galactosidases from different glycosyl hydrolase families and the catalytic mechanisms are summarized in detail to offer guidance for protein engineering. The properties and applications of β-galactosidases are discussed. Additionally, the latest progress in β-galactosidase engineering and the strategies employed are highlighted. Based on the combined analysis of structure information and catalytic mechanisms, the ultimate goal of this review is to furnish a thorough direction for β-galactosidases engineering and promote their application in the food and dairy industries.

Process modeling, environmental and economic sustainability of the valorization of whey and eucalyptus residues for resveratrol biosynthesis

Biomass is one of the renewable resources with the greatest potential, not only because of the possibility of energy recovery but also because of its content in components of interest. In this context, the regions of Galicia and Portugal have large areas of land dedicated to forestry, agriculture and livestock, and the large amount of waste generated represents a cost for the producer. The importance of these facts has aroused great interest in society to focus its interest on improving the current situation while seeking a benefit, both environmental and economic, from existing resources. That is why the integration of biotechnological processes and biorefinery for their valorization are considered key aspects in the way of producing bioproducts and bioenergy. This research article proposes a process for producing resveratrol from whey from the dairy industry and eucalyptus residues from forestry exploitation. In order to evaluate its suitability, a techno-economic analysis and an environmental assessment have been carried out using the Life Cycle Assessment (LCA) methodology. The results obtained show the potential of these scenarios both from the economic point of view, by obtaining a minimum sale price of resveratrol to ensure the viability of the process below the market average, and from the environmental point of view, being eucalyptus residues those that result in a lower contribution to the environment per unit of resveratrol produced. Future research should focus on increasing the throughput of the production process to increase its profitability and on reducing energy requirements throughout the process, as these have been the main critical points identified. In addition, following the sensitivity assessment, it has been concluded that opting for renewable energy is the most sustainable option.

Microalgal conversion of whey and lactose containing substrates: current state and challenges

Currently dairy processing by-products, such as whey, still propose a significant threat to the environment if unproperly disposed. Microalgal bioconversion of such lactose containing substrates can be used for production of valuable microalgae-derived bio-products as well as for significant reduction of environmental risks. Moreover, it could significantly reduce microalgae biomass production costs, being a significant obstacle in commercialization of many microalgae species. This review summarizes current knowledge on the use of lactose containing substrates, e.g. whey, for the production of value-added products by microalgae, including information on producer cultures, fermentation methods and cultivation conditions, bioprocess productivity and ability of microalgal cultures to produce β-galactosidases. It can be stated, that despite several limitations lactose-containing substrates can be successfully used for both-the production of microalgal biomass and removal of high amounts of excess nutrients from the cultivation media. Moreover, co-cultivation of microalgae and other microorganisms can further increase the removal of nutrients and the production of biomass. Further investigations on lactose metabolism by microalgae, selection of suitable strains and optimisation of the cultivation process is required in order to enable large-scale microalgae production on these substrates.

Ganoderma lucidum Mycelia Mass and Bioactive Compounds Production through Grape Pomace and Cheese Whey Valorization

Numerous compounds obtained from the medicinal mushroom Ganoderma lucidum have evidenced renowned bioactive characteristics. Controlled fermentation to generate fungal mycelia confers several advantages, specifically when the valorization of agro-industrial streams as fermentation feedstocks is included. Submerged fermentation of a newly isolated Greek strain of G. lucidum was performed using conventional synthetic media and, also, grape pomace extract (GPE) and cheese whey permeate (CWP) under static and shaking conditions. Under shaking conditions, maximum biomass with GPE and supplementation with organic nitrogen reached 17.8 g/L. The addition of an elicitor in CWP resulted in a significant improvement in biomass production that exceeded synthetic media. Overall, agitation demonstrated a positive impact on biomass productivity and, therefore, on process optimization. Crude intracellular and extracellular polysaccharides were extracted and evaluated regarding antioxidant activity and polysaccharide and protein content. FTIR analysis confirmed the preliminary chemical characterization of the crude extracts. This study introduces the design of a bioprocessing scenario to utilize food industry by-products as onset feedstocks for fungal bioconversions to obtain potential bioactive molecules within the concept of bioeconomy.

Effect of Fermentation with Streptococcus thermophilus Strains on In Vitro Gastro-Intestinal Digestion of Whey Protein Concentrates

Three Streptococcus thermophilus strains, namely RBC6, RBC20, and RBN16, were proven to release bioactive peptides during whey protein concentrate (WPC) fermentation, resulting in WPC hydrolysates with biological activities. However, these bioactive peptides can break down during gastro-intestinal digestion (GID), hindering the health-promoting effect of fermented WPC hydrolysates in vivo. In this work, the effect of simulated GID on three WPC hydrolysates fermented with S. thermophilus strains, as well as on unfermented WPC was studied in terms of protein hydrolysis, biological activities, and peptidomics profiles, respectively. In general, WPC fermentation enhanced protein hydrolysis compared to unfermented WPC. After in vitro GID, WPC fermented with S. thermophilus RBC20 showed the highest antioxidant activity, whereas WPC fermented with strain RBC06 displayed the highest angiotensin-converting enzyme (ACE)- and dipeptidyl peptidase IV (DPP-IV)-inhibitory activities. Peptidomics analysis revealed that all digested WPC samples were highly similar to each other in peptide profiles, and 85% of the 46 identified bioactive peptides were shared among fermented and unfermented samples. However, semi-quantitative analysis linked the observed differences in biological activities among the samples to differences in the amount of bioactive peptides. The anti-hypertensive peptides VPP and IPP, as well as the DPP-IV-inhibitory peptide APFPE, were quantified. In conclusion, WPC fermentation with S. thermophilus positively impacted protein hydrolysis and bioactive peptide release during GID.

Nondairy food applications of whey and milk permeates: Direct and indirect uses

Permeates are generated in the dairy industry as byproducts from the production of high-protein products (e.g., whey or milk protein isolates and concentrates). Traditionally, permeate was disposed of as waste or used in animal feed, but with the recent move toward a "zero waste" economy, these streams are being recognized for their potential use as ingredients, or as raw materials for the production of value-added products. Permeates can be added directly into foods such as baked goods, meats, and soups, for use as sucrose or sodium replacers, or can be used in the production of prebiotic drinks or sports beverages. In-direct applications generally utilize the lactose present in permeate for the production of higher value lactose derivatives, such as lactic acid, or prebiotic carbohydrates such as lactulose. However, the impurities present, short shelf life, and difficulty handling these streams can present challenges for manufacturers and hinder the efficiency of downstream processes, especially compared to pure lactose solutions. In addition, the majority of these applications are still in the research stage and the economic feasibility of each application still needs to be investigated. This review will discuss the wide variety of nondairy, food-based applications of milk and whey permeates, with particular focus on the advantages and disadvantages associated with each application and the suitability of different permeate types (i.e., milk, acid, or sweet whey).

Targeted gene manipulation of Leloir pathway genes for the constitutive expression of β-galactosidase and its transgalactosylation product galacto-oligosaccharides from Kluyveromyces lactis GG799 and knockout strains

Galacto-oligosaccharides (GOS) are used as prebiotic ingredients in various food and pharmaceutical industry. At present, production of GOS involves the enzymatic transformation of lactose by transgalactosylation using β-galactosidase. The yeast Kluyveromyces lactis can utilize lactose as its carbon and energy source. In this species lactose is hydrolyzed by an intracellular β-galactosidase (EC 3.2.1.23) which is induced by its substrate and related compounds like galactose. The molecular details of gene regulation in kluyveromyces lactis, we have used multiple knockout approaches to study the constitutive expression by which galactose induces β-galactosidase. The present study involved carrying out to a method of enhancing the constitutive expression of β-galactosidase through galactose induction and its trans-galactosylation reaction for the production of galacto-oligosaccharides (GOS) in Kluyveromyces lactis (K. Lactis) by applying a knockout based approach on Leloir pathway genes based on fusion-overlap extension polymerase chain reaction and transformation into its genome. The k.lactis strain subjected to Leloir pathway genes knockout, resulted in the accumulation of galactose intracellularly and this internal galactose acts as an inducer of galactose regulon for constitutive expression of β-galactosidase at early stationary phase was due to the positive regulatory function of mutant gal1p, gal7p and both. These resulted strains used for trans-galactosylation of lactose by β - galactosidase is characterized for the production of galacto-oligosaccharides. Galactose-induced constitutive expression of β-galactosidase during the early stationary phase of knockout strains was analysed qualitatively & quantitatively. The activity of β-galactosidase of wild type, gal1z, gal7k and gal1z & gal7k strains were 7, 8, 9 and 11 U/ml respectively using high cell density cultivation medium. Based on these expression differences in β-galactosidase, the trans-galactosylation reaction for GOS production and percentage yield of GOS were compared at 25% w/v of lactose. The percentage yield of GOS production of wild type, Δgal1z Lac4+, Δgal7k Lac4++ and Δgal1z Δgal7k Lac4+++mutants strains were 6.3, 13, 17 and 22 U/ml, respectively. Therefore, we propose that the availability of galactose can be used for constitutive over expression of β - galactosidase in Leloir pathway engineering applications and also for GOS production. Further, increased expression of β - galactosidases can be used in dairy industry by-products like whey to produce added value products such as galacto-oligosaccharides.

Acetic acid bacteria in agro-wastes: from cheese whey and olive mill wastewater to cellulose

In this study, cheese whey and olive mill wastewater were investigated as potential feedstocks for producing bacterial cellulose by using acetic acid bacteria strains. Organic acids and phenolic compounds composition were assayed by high-pressure liquid chromatography. Fourier-transform infrared spectroscopy, scanning electron microscopy, and X-ray diffraction were used to investigate modifications in bacterial cellulose chemical and morphological structure. Cheese whey was the most efficient feedstock in terms of bacterial cellulose yield (0.300 g of bacterial cellulose/gram of carbon source consumed). Bacterial cellulose produced in olive mill wastewater presented a more well-defined network compared to pellicles produced in cheese whey, resulting in a smaller fiber diameter in most cases. The analysis of bacterial cellulose chemical structure highlighted the presence of different chemical bonds likely to be caused by the adsorption of olive mill wastewater and cheese whey components. The crystallinity ranged from 45.72 to 80.82%. The acetic acid bacteria strains used in this study were characterized by 16S rRNA gene sequencing, allowing to assign them to Komagataeibacter xylinus and Komagataeibacter rhaeticus species. This study proves the suitability to perform sustainable bioprocesses for producing bacterial cellulose, combining the valorisation of agro-wastes with microbial conversions carried out by acetic acid bacteria. The high versatility in terms of yield, morphology, and fiber diameters obtained in cheese whey and olive mill wastewater contribute to set up fundamental criteria for developing customized bioprocesses depending on the final use of the bacterial cellulose. KEY POINTS: • Cheese whey and olive mill wastewater can be used for bacterial cellulose production. • Bacterial cellulose structure is dependent on the culture medium. • Komagataeibacter strains support the agro-waste conversion in bacterial cellulose.

Sustainable Approaches in Whey Cheese Production: A Review

Whey cheeses have been produced from the very early steps of cheesemaking practices as a sustainable way to utilize whey, which is the main by-product of cheesemaking. Traditional whey cheeses, manufactured with similar processes, are Ricotta, Ricotta salata or Ricottone, and Ricotta fresca in Italy; Anthotyros, Myzithra, Manouri, Xynomyzithra, and Urda in Greece; Urda in Serbia and Romania as well as in other countries such as Israel; Lor in Turkey; Anari in Cyprus; Skuta in Croatia and Serbia; Gjetost and Brunost in Norway; Mesost and Messmör in Sweden; Mysuostur in Iceland; Myseost in Denmark; Requeijão in Portugal; and Requesón in Spain and Mexico. The production of whey cheese is based on the denaturation of whey proteins by heating to 88–92 °C. The specific processing conditions and aspects of the microbiology of whey cheeses are discussed. The special characteristics of whey cheeses, which are high pH and high moisture content, make them susceptible to microbial growth. Due to the limited shelf life of these products, extended research has been carried out to extend the shelf life of whey cheese. The sustainable preservation approaches, such as modified atmosphere packaging, addition of herbs and/or plant extracts, and bio-preservation methods are reviewed. Moreover, novel whey cheeses focused on functional properties have developed during the last 10 years.

Valorization of Food Waste to Produce Value-Added Products Based on Its Bioactive Compounds

The rapid growth of the global population and changes in lifestyle have led to a significant increase in food waste from various industrial, agricultural, and household sources. Nearly one-third of the food produced annually is wasted, resulting in severe resource depletion. Food waste contains rich organic matter, which, if not managed properly, can pose a serious threat to the environment and human health, making the proper disposal of food waste an urgent global issue. However, various types of food waste, such as waste from fruit, vegetables, grains, and other food production and processing, contain important bioactive compounds, such as polyphenols, dietary fiber, proteins, lipids, vitamins, organic acids, and minerals, some of which are found in greater quantities in the discarded parts than in the parts accepted by the market. These bioactive compounds offer the potential to convert food waste into value-added products, and fields including nutritional foods, bioplastics, bioenergy, biosurfactants, biofertilizers, and single cell proteins have welcomed food waste as a novel source. This review reveals the latest insights into the various sources of food waste and the potential of utilizing bioactive compounds to convert it into value-added products, thus enhancing people’s confidence in better utilizing and managing food waste.

Sustainable production of biosurfactants via valorisation of industrial wastes as alternate feedstocks

Globally, the rapid increase in the human population has given rise to a variety of industries, which have produced a variety of wastes. Due to their detrimental effects on both human and environmental health, pollutants from industry have taken centre stage among the various types of waste produced. The amount of waste produced has therefore increased the demand for effective waste management. In order to create valuable chemicals for sustainable waste management, trash must be viewed as valuable addition. One of the most environmentally beneficial and sustainable choices is to use garbage to make biosurfactants. The utilization of waste in the production of biosurfactant provides lower processing costs, higher availability of feedstock and environmental friendly product along with its characteristics. The current review focuses on the use of industrial wastes in the creation of sustainable biosurfactants and discusses how biosurfactants are categorized. Waste generation in the fruit industry, agro-based industries, as well as sugar-industry and dairy-based industries is documented. Each waste and wastewater are listed along with its benefits and drawbacks. This review places a strong emphasis on waste management, which has important implications for the bioeconomy. It also offers the most recent scientific literature on industrial waste, including information on the role of renewable feedstock for the production of biosurfactants, as well as the difficulties and unmet research needs in this area.

Redefining methods for augmenting lactic acid bacteria robustness and phenyllactic acid biocatalysis: Integration valorizes simplicity

The production of phenyllactic acid (PLA) has been reported by several researchers, but so far, no mention has been made of augmented PLA production using an orchestrated assembly of simple techniques integrated to improve lactic acid bacteria (LAB) metabolism for the same. This review summarizes sequentially tailoring LAB growth and metabolism for augmented PLA catalysis through several strategies like monitoring LAB sustenance by choosing appropriate starter PLA-producing LAB strains isolated from natural environments, with desirably fastidious growth rates, properties like acidification, proteolysis, bacteriophage-resistance, aromatic/texturing-features, etc.; entrapping chosen LAB strains in novel cryogels and/or co-cultivating two/more LAB strains to improve their biotransformation potential and promote growth dependency/sustainability; adopting adaptive evolution methods designed to improve LAB strains under selection pressure inducing desired phenotypes tolerant to stress factors like heat, salt, acid, and solvent; monitoring physico-chemical LAB fermentation factors like temperature, pH, dissolved oxygen content, enzymes, and cofactors for PLA biosynthesis; and modulating purification/downstream processes to extract substantial PLA yields. This review paper serves as a comprehensive preliminary guide that can evoke a strategic experimental plan to produce industrial-scale PLA yields using simple techniques orchestrated together in the pursuit of conserving time, effort, and resources.

Production of biopolymers from food waste: Constrains and perspectives

Food is an essential commodity for the survival of any form of life on earth. Yet generation of plethora of food waste has significantly elevated the global concern for food scarcity, human and environment deterioration. Also, increasing use of polymers derived from petroleum hydrocarbons has elevated the concerns towards the depletion of this non-renewable resource. In this review, the use of waste food for the production of bio-polymers and their associated challenges has been thoroughly investigated using scientometric analysis. Various categories of food waste including fruit, vegetable, and oily waste can be employed for the production of different biopolymers including polyhydroxyalkanoates, starch, cellulose, collagen and others. The advances in the production of biopolymers through chemical, microbial or enzymatic process that increases the acceptability of these biopolymers has been reviewed. The comprehensive compiled information may assist researchers for addressing and solving the issues pertaining to food wastage and fossil fuel depletion.

Novel Probiotic/Bacterial Cellulose Biocatalyst for the Development of Functional Dairy Beverage

The development of innovative functional products with potential health benefits, under the concept of bio-economy, is flourishing. This study undertook an evaluation of non-dairy lactobacilli Lactiplantibacillus pentosus B329 and Lactiplantibacillus plantarum 820 as “ready to use” starter cultures. Lactic acid bacteria (LAB) cultures were evaluated for their fermentation efficiency, before and after freeze-drying, using cheese whey (CW) as a fermentation substrate and subsequent immobilization on bacteria cellulose (BC) to produce a novel biocatalyst. The biocatalyst was applied in functional sour milk production and compared with free cells via the assessment of physicochemical and microbiological properties and sensory evaluation. Evidently, LAB strains exhibited high fermentative activity before and after freeze-drying. Results of a 5-month storage stability test showed that viability was 19% enhanced by immobilization on BC, supporting the concept of “ready to use” cultures for the production of fermented beverages. Likewise, sour milk produced by the BC biocatalyst presented higher organoleptic scores, compared to the free cells case, whereas immobilization on BC enhanced probiotic viability during post-fermentation storage (4 °C, 28 days). The obtained high viability (>107 log cfu/g) demonstrated the efficacy of the proposed bioprocess for the production of functional/probiotic-rich beverages. Ultimately, this work presents a consolidated scheme that includes the advantages and the cooperative effect of probiotic LAB strains combined with a functional biopolymer (BC) towards the formulation of novel functional products that coincide with the pillars of food systems sustainability.

Recycling Food Waste and Saving Water: Optimization of the Fermentation Processes from Cheese Whey Permeate to Yeast Oil

With the aim of developing bioprocesses for waste valorization and a reduced water footprint, we optimized a two-step fermentation process that employs the oleaginous yeast Cutaneotrichosporon oleaginosus for the production of oil from liquid cheese whey permeate. For the first step, the addition of urea as a cost-effective nitrogen source allowed an increase in yeast biomass production. In the second step, a syrup from candied fruit processing, another food waste supplied as carbon feeding, triggered lipid accumulation. Consequently, yeast lipids were produced at a final concentration and productivity of 38 g/L and 0.57 g/L/h respectively, which are among the highest reported values. Through this strategy, based on the valorization of liquid food wastes (WP and mango syrup) and by recovering not only nutritional compounds but also the water necessary for yeast growth and lipid production, we addressed one of the main goals of the circular economy. In addition, we set up an accurate and fast-flow cytometer method to quantify the lipid content, avoiding the extraction step and the use of solvents. This can represent an analytical improvement to screening lipids in different yeast strains and to monitoring the process at the single-cell level.

Moesziomyces spp. cultivation using cheese whey: new yeast extract-free media, β-galactosidase biosynthesis and mannosylerythritol lipids production

Mannosylerythritol lipids (MELs) are biosurfactants with excellent biochemical properties and a wide range of potential applications. However, high production costs, low productivity and unsatisfactory scale-up production have hampered commercial adoption. Herein, we report for the first time the β-galactosidase production by Moesziomyces spp. from different sugars (D-galactose, D-glucose and D-lactose), with D-galactose being the best β-galactosidase inducer, with 11.2 and 63.1 IU/mgbiomass, for Moesziomyces aphidis 5535 T and Moesziomyces antarcticus 5048 T, respectively. The production of this enzyme allows to break down D-lactose and thus to produce MEL directly from D-lactose or cheese whey (a cheese industry by-product). Remarkably, when CW was used as sole media component (carbon and mineral source), in combination with waste frying oil, MEL productivities were very close (1.40 and 1.31 gMEL/L/day) to the ones obtained with optimized medium containing yeast extract (1.92 and 1.50 gMEL/gsusbtrate), both for M. antarcticus and M. aphidis. The low-cost, facile and efficient process which generates large amounts of MELs potentiates its industrialization.

Supplementary Information

The online version contains supplementary material available at 10.1007/s13399-022-02837-y.

Efficient Production of Broad-Spectrum Antimicrobials by Paenibacillus polymyxa OSY-EC Using Acid Whey-Based Medium and Novel Antimicrobial Concentration Approach

Production of some antimicrobial peptides by bacterial producers is a resource-intensive process, thus, using inexpensive growth media and simplifying antimicrobial extraction and down-stream processing are highly desirable. Acid whey, a dairy industry waste, is explored as a medium for production of broad-spectrum antimicrobials from selected bacteriocinogenic bacteria. Neutralized and yeast extract-supplemented acid whey was suitable for production of antimicrobials by four tested strains, but Paenibacillus polymyxa OSY-EC was the most prolific antimicrobial producer. Concentrating synthesized antimicrobials during culture incubation using beads of polymeric adsorbent resin, followed by solvent extraction and freeze-drying, resulted in antimicrobials-rich powder (AMRP). Under these conditions, P. polymyxa OSY-EC produced paenibacillin, polymyxin E, and fusaricidin, which are active against Gram-positive and Gram-negative bacteria and fungi, respectively. When media containing 2x and 4x minimum inhibitory concentrations of AMRP were inoculated with Listeria innocua and Escherichia coli, microbial populations decreased by ≥4-log CFU ml-1 in tryptic soy broth and ≥3.5-log CFU ml-1 in milk. The antimicrobial mechanism of action of AMRP solutions was attributed to the disruption of cytoplasmic membrane of indicator strains, L. innocua and E. coli. These findings exemplify promising strategies for valorization of acid whey via microbial bioreactions to yield potent antimicrobials.

Valorisation of Bovine Sweet Whey and Sunflower Press Cake Blend through Controlled Fermentation as Platform for Innovative Food Materials

The current environmental challenge is pushing food systems towards more sustainable models of production that require reorganizing of processes by re-using side products still containing nutrients. This work aimed at valorising a mix of bovine sweet whey and sunflower press cake, through targeted fermentation. After preliminary screening based on growth rate, final pH, lactose/galactose assimilation, phytase activity, six Lactic Acid Bacteria strains (Lacticaseibacillus casei, L. paracasei (2), Lactococcus lactis, Lentilactobacillus parakefiri and Leuconostoc pseudomesenteroides) and three yeasts (Kluyveromyces lactis, K. marxianus and Torulaspora delbrueckii) were co-cultivated in pairs in microcosms (1-part ground press cake: 4-parts whey). All tested microorganisms were able to grow and acidify the blend: the LAB counts increased during the incubation (26 °C for 48 h) of +2.80 log CFU/g, whereas yeasts counts were of +1.98 log CFU/g, with significant differences among the different associations (p < 0.01). Mould counts were always <3 log CFU/g. Interestingly, the bacterial contaminants count significantly varied in samples with different pairs of strains (p < 0.001). Acidification level, acetic acid and ethanol contents were the limiting factors affecting the growth of spoilage micro-organisms. Best performances were attained in microcosms inoculated with L. lactis or L. paracasei and K. lactis or K. marxianus.

Molecular modeling of lactoferrin for food and nutraceutical applications: insights from in silico techniques

Lactoferrin is a protein, primarily found in milk that has attracted the interest of the food industries due to its health properties. Nevertheless, the instability of lactoferrin has limited its commercial application. Recent studies have focused on encapsulation to enhance the stability of lactoferrin. However, the molecular insights underlying the changes of structural properties of lactoferrin and the interaction with protectants remain poorly understood. Computational approaches have proven useful in understanding the structural properties of molecules and the key binding with other constituents. In this review, comprehensive information on the structure and function of lactoferrin and the binding with various molecules for food purposes are reviewed, with a special emphasis on the use of molecular dynamics simulations. The results demonstrate the application of modeling and simulations to determine key residues of lactoferrin responsible for its stability and interactions with other biomolecular components under various conditions, which are also associated with its functional benefits. These have also been extended into the potential creation of enhanced lactoferrin for commercial purposes. This review provides valuable strategies in designing novel nutraceuticals for food science practitioners and those who have interests in acquiring familiarity with the application of computational modeling for food and health purposes.

The dairy biorefinery: Integrating treatment process for Tunisian cheese whey valorization

In order to set up a cost-efficient biorefinery in a Tunisian dairy industry, the production unit effluents are recovered. The main objective is to develop an optimum method for the production of bioethanol from whey. An energy analysis as well as environmental and economic analyses are performed for a bioethanol production plant. Four production scenarios are examined in order to determine the most provident as well as the less polluting ones. The process and cost models were developed using SuperPro Designer software which a simulation program that is able to estimate both process and economic parameters. This software uses energy and mass balances. The model can be used to assess the efficiency, the resources consumption, the profitability and the environmental impact of each scenario. The results demonstrate that the third scenario, in which a reverse osmosis procedure is added to concentrate the whey, a continuous stoichiometric reaction procedure is integrated to model the biotransformation in the fermenter and where streams are added in order to recycle the biomass, produces the highest amount of bioethanol with 1.65 MT/year but the second one (where no streams were added) is the most profitable one with revenues as high as 570 000 $/year. The corresponding cost of ethanol production is 0.271 US $ ethanol per liter. The net present value (NPV) and the return on investment (ROI) of each scenario are positive. Such result indicates that all these investments could be undertaken in order to find an eco-friendly issue for the dairy industry effluents. Cheese whey could serve as an alternative raw material for producing ethanol.

Milk Whey Hydrolysates as High Value-Added Natural Polymers: Functional Properties and Applications

There are two types of milk whey obtained from cheese manufacture: sweet and acid. It retains around 55% of the nutrients of the milk. Milk whey is considered as a waste, creating a critical pollution problem, because 9 L of whey are produced from every 10 L of milk. Some treatments such as hydrolysis by chemical, fermentation process, enzymatic action, and green technologies (ultrasound and thermal treatment) are successful in obtaining peptides from protein whey. Milk whey peptides possess excellent functional properties such as antihypertensive, antiviral, anticancer, immunity, and antioxidant, with benefits in the cardiovascular, digestive, endocrine, immune, and nervous system. This review presents an update of the applications of milk whey hydrolysates as a high value-added peptide based on their functional properties.

Whey protein films reinforced with bacterial cellulose nanowhiskers: Improving edible film properties via a circular economy approach

Edible films were developed using whey protein concentrate (WPC) and a natural bio-polymer, namely bacterial cellulose (BC). BC was produced via fermentation from orange peels and subsequently acid-hydrolyzed to obtain BC nanowhiskers (BCNW) with high crystallinity (XRD analysis). Morphology of BCNW was analyzed by SEM, TEM, and AFM. WPC/BCNW film composites, containing different amounts of BCNW (0.5-15%, w/w) were developed and characterized. WPC/BCNW film composite was analyzed by Raman spectroscopy, indicating the successful incorporation and the homogenous distribution of BCNW into the WPC film matrix. Mechanical characterization showed that BCNW behaved as a reinforcing filler in the WPC film, increasing tensile strength and Young's modulus by 32% and 80%, respectively. In addition, water vapor permeability was reduced by 33.9% upon the addition of 0.5% BCNW. This study presented a sustainable approach towards the production of WPC films with improved tensile and water barrier properties, suggesting its potential application as a packaging material.

Potential utilization of dairy industries by-products and wastes through microbial processes: A critical review

The dairy industry generates excessive amounts of waste and by-products while it gives a wide range of dairy products. Alternative biotechnological uses of these wastes need to be determined to aerobic and anaerobic treatment systems due to their high chemical oxygen demand (COD) levels and rich nutrient (lactose, protein and fat) contents. This work presents a critical review on the fermentation-engineering aspects based on defining the effective use of dairy effluents in the production of various microbial products such as biofuel, enzyme, organic acid, polymer, biomass production, etc. In addition to microbial processes, techno-economic analyses to the integration of some microbial products into the biorefinery and feasibility of the related processes have been presented. Overall, the inclusion of dairy wastes into the designed microbial processes seems also promising for commercial approaches. Especially the digestion of dairy wastes with cow manure and/or different substrates will provide a positive net present value (NPV) and a payback period (PBP) less than 10 years to the plant in terms of biogas production.

Biosurfactant Production from Lactobacilli: an Insight on the Interpretation of Prevailing Assessment Methods

Biosurfactants constitute amphiphilic molecules, receiving increased attention as environmentally benign, biodegradable alternatives to substitute for the petroleum derived counterparts in food, pharmaceutical and cosmetics applications. However, their high production cost hinders industrial production. In this study, fifty GRAS lactobacilli strains were screened for their ability to produce biosurfactants, implementing different substrates. Cheese whey permeate (CWP) was also assessed as a low-cost and inherent lactobacilli substrate, aiming to mitigate its polluting impact, expand valorization strategies, alleviate costs deriving from commercial supplements and enhance overall sustainability. Surface tension, emulsification activity (E24) and oil displacement were deployed to identify the most promising candidates. Results reveal surface tension as the most robust method and underline the effect of substrate on biosurfactant synthesis. Likewise, this study indicates the fundamental role of including the final fermentation substrate (CWP) during strain selection to avoid misinterpretation of results and enhance subsequent bioprocess integration.

Valorization of dairy waste and by-products through microbial bioprocesses

Waste is an inherent and unavoidable part of any process which can be attributed to various factors such as process inefficiencies, usability of resources and discarding of not so useful parts of the feedstock. Dairy is a burgeoning industry following the global population growth, resulting in generation of waste such as wastewater (from cleaning, processing, and maintenance), whey and sludge. These components are rich in nutrients, organic and inorganic materials. Additionally, the presence of alkaline and acidic detergents along with sterilizing agents in dairy waste makes it an environmental hazard. Thus, sustainable valorization of dairy waste requires utilization of biological methods such as microbial treatment. This review brings forward the current developments in utilization and valorization of dairy waste through microbes. Aerobic and anaerobic treatment of dairy waste using microbes can be a sustainable and green method to generate biofertilizers, biofuels, power, and other biobased products.

Trends in lactose-derived bioactives: synthesis and purification

Lactose obtained from cheese whey is a low value commodity despite its great potential as raw material for the production of bioactive compounds. Among them, prebiotics stand out as valuable ingredients to be added to food matrices to build up functional foods, which currently represent the most active sector within the food industry. Functional foods market has been growing steadily in the recent decades along with the increasing awareness of the World population about healthy nutrition, and this is having a strong impact on lactose-derived bioactives. Most of them are produced by enzyme biocatalysis because of molecular precision and environmental sustainability considerations. The current status and outlook of the production of lactose-derived bioactive compounds is presented with special emphasis on downstream operations which are critical because of the rather modest lactose conversion and product yields that are attainable. Even though some of these products have already an established market, there are still several challenges referring to the need of developing better catalysts and more cost-effective downstream operations for delivering high quality products at affordable prices. This technological push is expected to broaden the spectrum of lactose-derived bioactive compounds to be produced at industrial scale in the near future.

Graphical abstract

Development of a Continuous System for 2-Phenylethanol Bioproduction by Yeast on Whey Permeate-Based Medium

2-Phenylethanol (2-PE) is an alcohol with a rosy scent and antimicrobial activity, and therefore, it is widely used in the food and cosmetic industries as an aroma and preservative. This work was aimed to draw up a technology for 2-PE bioproduction on whey permeate, which is waste produced by the dairy industry, rich in lactase and proteins. Its composition makes it a harmful waste to dispose of; however, with a properly selected microorganism, it could be converted to a value-added product. Herein, two yeast Kluyveromyces marxianus strains and one Kluyveromyces lactis, isolated from dairy products, were tested for 2-PE production, firstly on standard media and then on whey permeate based media in batch cultures. Thereafter, the 2-PE bioproduction in a continuous system in a 4.8 L bioreactor was developed, and subsequently, the final product was recovered from culture broth. The results showed that the yield of 2-PE production increased by 60% in the continuous culture compared to batch culture. Together with a notable reduction of chemical oxygen demand for whey permeate, the present study reports a complete, effective, and environmentally friendly strategy for 2-PE bioproduction with a space-time yield of 57.5 mg L^-1 h^-1.

Production of bacterial cellulose from glycerol: the current state and perspectives

Current research in industrial microbiology and biotechnology focuses on the production of biodegradable microbial polymers as an environmentally friendly alternative to the still dominant fossil hydrocarbon-based plastics. Bacterial cellulose (BC) is important among microbial polymers due to its valuable properties and broad applications in variety of fields from medical to industrial technologies. However, the increase in BC production and its wider deployment is still limited by high costs of traditionally used raw materials. It is therefore necessary to focus on less expensive inputs, such as agricultural and industrial by-products or waste including the more extended use of glycerol. It is the environmentally harmful by-product of biofuel production and reducing it will also reduce the risk of environmental pollution. The experimental data obtained so far confirm that glycerol can be used as the renewable carbon source to produce BC through more efficient and environmentally friendly bioprocesses. This review summarizes current knowledge on the use of glycerol for the production of commercially prospective BC, including information on producer cultures, fermentation modes and methods used, nutrient medium composition, cultivation conditions, and bioprocess productivity. Data on the use of some related sugar alcohols, such as mannitol, arabitol, xylitol, for the microbial synthesis of cellulose are also considered, as well as the main methods and applications of glycerol pre-treatment briefly described.

Food wastes as natural sources of lactic acid bacterial exopolysaccharides for the functional food industry: A review

Exopolysaccharides (EPSs) synthesized by lactic acid bacteria (LAB), have recently received much interest because of their various functional features in several industries. Food wastes (FWs) have become a major source of worry, as they can cause serious environmental contamination if improperly disposed. The utilization of these FWs is an excellent choice (approach) for producing value-added products such as EPSs, which will efficiently remediate wastes. The overall EPSs yield for the selected producers is strain-specific, and is heavily influenced by the nutritional and growing conditions used. This review emphasizes what is currently known about LAB's ability to generate economically relevant EPSs from FWs. In addition, a concise overview of the food industry, packaging, pharmaceutical and clinical applications application is discussed.

A Comprehensive Bioprocessing Approach to Foster Cheese Whey Valorization: On-Site β-Galactosidase Secretion for Lactose Hydrolysis and Sequential Bacterial Cellulose Production

Cheese whey (CW) constitutes a dairy industry by-product, with considerable polluting impact, related mostly with lactose. Numerous bioprocessing approaches have been suggested for lactose utilization, however, full exploitation is hindered by strain specificity for lactose consumption, entailing a confined range of end-products. Thus, we developed a CW valorization process generating high added-value products (crude enzymes, nutrient supplements, biopolymers). First, the ability of Aspergillus awamori to secrete β-galactosidase was studied under several conditions during solid-state fermentation (SSF). Maximum enzyme activity (148 U/g) was obtained at 70% initial moisture content after three days. Crude enzymatic extracts were further implemented to hydrolyze CW lactose, assessing the effect of hydrolysis time, temperature and initial enzymatic activity. Complete lactose hydrolysis was obtained after 36 h, using 15 U/mL initial enzymatic activity. Subsequently, submerged fermentations were performed with the produced hydrolysates as onset feedstocks to produce bacterial cellulose (5.6–7 g/L). Our findings indicate a novel approach to valorize CW via the production of crude enzymes and lactose hydrolysis, aiming to unfold the output potential of intermediate product formation and end-product applications. Likewise, this study generated a bio-based material to be further introduced in novel food formulations, elaborating and conforming with the basic pillars of circular economy.