Biorefinery of brewery spent grain to obtain bioproducts with high value-added in the market

The brewery industry is under economic and environmental pressure to minimize residual management costs, particularly brewery spent grain (BSG), which accounts for 80-85% (w/w) of the total by-products generated. BSG is a lignocellulosic material primarily composed of carbohydrates, proteins and lipids. Developing a biorefinery model for conversion of BSG into value-added products is a plausible idea. Previous work optimized the pretreatment of BSG with the ionic liquid [N1112OH][Gly] and further release of fermentable sugar-containing solutions by enzymatic hydrolysis, using an enzymatic cocktail obtained by solid-state fermentation of BSG with Aspergillus brasiliensis CECT 2700 and Trichoderma reesei CECT 2414. The current work ends the biorefinery process, studying the fermentation of these culture media with two LAB strains, Lactobacillus pentosus CECT 4023 and Lactobacillus plantarum CECT 221, from which the production of organic acids, bacteriocins, and microbial biosurfactants (mBS) was obtained. In addition to the bacteriocin activity observed, a mass balance of the whole biorefinery process quantified the production of 106.4 g lactic acid and 6.76 g mBS with L. plantarum and 116.1 g lactic acid and 4.65 g mBS with L. pentosus from 1 kg of dry BSG. Thus, BSG shows a great potential for waste valorization, playing a major role in the implementation of biomass biorefineries in circular bioeconomy.

Biorefinery of Brewery Spent Grain by Solid-State Fermentation and Ionic Liquids

Novel environmentally friendly pretreatments have been developed in recent years to improve biomass fractionation. Solid-state fermentation (SSF) and treatment with ionic liquids show low environmental impact and can be used in biorefinery of biomass. In this work, these processes were assessed with brewery spent grain (BSG). First, BSG was used as a substrate to produce cellulases and xylanases by SSF with the fungi Aspergillus brasiliensis CECT 2700 and Trichoderma reesei CECT 2414. Then, BSG was pretreated with the ionic liquid [N₁₁₁₂OH][Gly] and hydrolyzed with the crude enzymatic extracts. Results showed that SSF of BSG with A. brasiliensis achieved the highest enzyme production; meanwhile, the pretreatment with ionic liquids allowed glucan and xylan fractions to increase and reduce the lignin content. In addition, a mixture of the extracts from both fungi in a ratio of 2.5:0.5 Aspergillus/Trichoderma (v/v) efficiently hydrolyzed the BSG previously treated with the ionic liquid [N₁₁₁₂OH][Gly], reaching saccharification percentages of 80.68%, 54.29%, and 19.58% for glucan, xylan, and arabinan, respectively. In conclusion, the results demonstrated that the BSG biorefinery process developed in this work is an effective way to obtain fermentable sugar-containing solutions, which can be used to produce value-added products.

Influence of Casein Hydrolysates and Yeast on the Rheological Properties of Wheat Dough

The influence of casein hydrolysates (CHs) and yeast on the viscoelasticity of wheat dough at 25 °C were analysed. Three wheat doughs were studied: the unyeasted dough (UYD), the unyeasted dough with CHs (UYD-C) and the yeasted dough (YD). The characteristic parameters in the linear viscoelastic range (LVER) were analysed by stress sweep at 6.3 rad/s: UYD-C dough exhibited higher values of stress (σ_max) and strain (γ_max) amplitudes, and softer gel network (lower complex modulus, G*) comparing with UYD dough. The oscillatory data suggest that CHs would work as (energy and time) stabilising-agents based on the greatest reticular energy (E parameter) and the lowest frequency dependence of phase angle (δ) at the low frequency range. The rotatory tests show that CHs may act as shear thinning agents in the gluten-starch network, facilitating the solid-fluid transition at the yield point (UYD-C dough). The yeasted dough (YD) exhibited a more shear sensitive structure, evidenced in the highest influence of frequency on the elastic (G') and viscous (G″) parameters, and gel to sol transition at 0.23 rad/s was observed.

Batch and fed-batch production of probiotic biomass and nisin in nutrient-supplemented whey media

The production of a highly concentrated probiotic preparation of Lactococcus lactis CECT 539 was studied in both batch and realkalized fed-batch fermentations in diluted whey (DW) media (DW25, DW50, DW75, DW100, and DW125) supplemented with MRS broth nutrients (except glucose and Tween 80) at 25, 50, 75, 100, and 125% of their standard concentrations in the complex medium. The fed-batch culture using DW100 medium provided the highest concentrations of probiotic biomass (5.98 g/L) and nisin (258.47 BU/mL), which were obtained at lower production costs than those estimated for the fed-batch culture in DW medium. The batch and fed-batch cultures reduced the initial chemical oxygen demand (COD) of the media by 29.1-41.7% and 31.2-54.2%, respectively. Graphical abstract.

The Joint Effect of pH Gradient and Glucose Feeding on the Growth Kinetics of Lactococcus lactis CECT 539 in Glucose-Limited Fed-Batch Cultures

Two glucose-limited realkalized fed-batch cultures of Lactococcus lactis CECT 539 were carried out in a diluted whey medium (DW) using two different feeding media. The cultures were fed a mixture of a 400 g/l concentrated lactose and a concentrated mussel processing waste (CMPW, 101.72 g glucose/l) medium (fermentation I) or a CMPW medium supplemented with glucose and KH₂PO₄ up to concentrations of 400 g glucose/l and 3.21 g total phosphorus/l, respectively (fermentation II). For an accurate description and a better understanding of the kinetics of both cultures, the growth and product formation by L. lactis CECT 539 were both modelled, for the first time, as a function of the amounts of glucose (G) added and the pH gradient (VpH) generated in every realkalization and feeding cycle, by using an empirical polynomial model. With this modeling procedure, the kinetics of biomass, viable cell counts, nisin, lactic acid, acetic acid and butane-2,3-diol production in both cultures were successfully described (R ² values > 0.970) and interpreted for the first time. In addition, the optimum VpH and G values for each product were accurately calculated in the two realkalized fed-batch cultures. This approach appears to be useful for designing feeding strategies to enhance the productions of biomass, bacteriocin, and metabolites by the nisin-producing strain in wastes from the food industry.

Two glucose-limited realkalized fed-batch cultures of Lactococcus lactis CECT 539 were carried out in a diluted whey medium (DW) using two different feeding media. The cultures were fed a mixture of a 400 g/l concentrated lactose and a concentrated mussel processing waste (CMPW, 101.72 g glucose/l) medium (fermentation I) or a CMPW medium supplemented with glucose and KH₂PO₄ up to concentrations of 400 g glucose/l and 3.21 g total phosphorus/l, respectively (fermentation II). For an accurate description and a better understanding of the kinetics of both cultures, the growth and product formation by L. lactis CECT 539 were both modelled, for the first time, as a function of the amounts of glucose (G) added and the pH gradient (VpH) generated in every realkalization and feeding cycle, by using an empirical polynomial model. With this modeling procedure, the kinetics of biomass, viable cell counts, nisin, lactic acid, acetic acid and butane-2,3-diol production in both cultures were successfully described (R ² values > 0.970) and interpreted for the first time. In addition, the optimum VpH and G values for each product were accurately calculated in the two realkalized fed-batch cultures. This approach appears to be useful for designing feeding strategies to enhance the productions of biomass, bacteriocin, and metabolites by the nisin-producing strain in wastes from the food industry.

Enzymatic hydrolysis of brewer's spent grain to obtain fermentable sugars

Lignocellulosic biomass is a feedstock with the potential to be converted into value-added bioproducts. The use of enzymatic hydrolysis allows the cleavage of lignocellulose into their monomeric units, but there are some drawbacks that make its use in industrial biocatalysis unfeasible. In the present study, we describe the hydrolysis of brewer's spent grain (BSG) with an enzymatic cocktail produced by Aspergillus niger CECT 2700 and its comparison with commercial enzymes. In addition, it was determined whether pretreating the BSG (non-pressurized alkaline hydrolysis or treatment with cholinium glycinate ionic liquid) is necessary. Results show that both pretreatments enhanced xylose release (10.55 ± 0.07 g/L and 8.14 ± 0.13 g/L respectively), meanwhile the hydrolysis of raw BSG with the enzymatic cocktail produced solutions containing high levels of glucose (18.45 ± 1.66 g/L) and xylose (6.38 ± 0.26 g/L).

Simultaneous production of amylases and proteases by Bacillus subtilis in brewery wastes

The simultaneous production of amylase (AA) and protease (PA) activity by Bacillus subtilis UO-01 in brewery wastes was studied by combining the response surface methodology with the kinetic study of the process. The optimum conditions (T=36.0°C and pH=6.8) for high biomass production (0.92g/L) were similar to the conditions (T=36.8°C and pH=6.6) for high AA synthesis (9.26EU/mL). However, the maximum PA level (9.77EU/mL) was obtained at pH 7.1 and 37.8°C. Under these conditions, a considerably high reduction (between 69.9 and 77.8%) of the initial chemical oxygen demand of the waste was achieved. In verification experiments under the optimized conditions for production of each enzyme, the AA and PA obtained after 15h of incubation were, respectively, 9.35 and 9.87EU/mL. By using the Luedeking and Piret model, both enzymes were classified as growth-associated metabolites. Protease production delay seemed to be related to the consumption of non-protein and protein nitrogen. These results indicate that the brewery waste could be successfully used for a high scale production of amylases and proteases at a low cost.

Production and characterization of distilled alcoholic beverages obtained by solid-state fermentation of black mulberry (Morus nigra L.) and black currant (Ribes nigrum L.)

The present study was conducted to appraise the potential of black mulberry and black currant to be used as fermentation substrates for producing alcoholic beverages obtained by distillation of the fruits previously fermented with Sacchromyces cerevisiae IFI83. In the two distillates obtained, the volatile compounds that can pose health hazards are within the limits of acceptability fixed by the European Council (Regulation 110/2008) for fruit spirits. However, the amount of volatile substances in the black currant distillate (121.1 g/hL absolute alcohol (aa)) was lower than the minimum limit (200 g/hL aa) fixed by the aforementioned regulation. The mean volatile composition of both distillates was different from other alcoholic beverages such as four commercial Galician orujo spirits, Portuguese bagaceiras, and two distillates obtained from fermented whey and blackberry. The results obtained showed the feasibility for obtaining distillates from fermented black mulberry and black currant, which have their own distinctive characteristics.

Performance and intestinal coliform counts in weaned piglets fed a probiotic culture (Lactobacillus casei subsp. casei CECT 4043) or an antibiotic

The production of biomass and antibacterial extracellular products by Lactobacillus casei subsp. casei CECT 4043 was followed in both batch and in realkalized fed-batch cultures. Enhanced concentrations of biomass and antibacterial extracellular products were obtained with the use of the latter fermentation technique in comparison with the batch mode. The culture obtained by fed-batch fermentation was mixed with skim milk and used to prepare a probiotic feed for weaned piglets. To test the effect of the potentially probiotic culture of L. casei on body weight gain, feed intake, feed conversion efficiency, and on fecal coliform counts of piglets, two groups of animals received either feed supplemented with the probiotic preparation or avilamycin for 28 days. The control group was fed nonsupplemented feed. At the end of the administration period (day 28), the groups receiving probiotic and avilamycin exhibited the highest average body weight gain values, although the mean feed intake and feed conversion efficiency values were not different among the groups (P > 0.05). For the entire experimental period (42 days), the control group exhibited the lowest feed intake value, the probiotic group exhibited the highest feed conversion efficiency value, and the antibiotic group exhibited the highest body weight gain (P < 0.05). Interestingly, no significant difference in body weight gain was observed between the probiotic and the control groups by day 42 (P > 0.05). Fecal coliform values decreased (although not significantly) by day 28 in the three groups. However, the mean counts returned to pretreatment levels by day 42 in all groups.

Fed-batch pediocin production by Pediococcus acidilactici NRRL B-5627 on whey

Cell growth and pediocin production by Pediococcus acidilactici NRRL B-5627 on whey were compared by using batch fermentation and re-alkalized fed-batch fermentation. The batch fermentations were performed on DWG [DW (diluted whey) supplemented with 1% (w/v) glucose], DWYE [DW supplemented with 2% (w/v) yeast extract] and DWGYE (DW supplemented with 1% glucose plus 2% yeast extract) media. The fed-batch culture on DWYE medium was fed with a mixture of concentrated whey (48 g of total sugars/l) supplemented with 2% yeast extract and 400 g/l concentrated glucose. The re-alkalized fed-batch culture was characterized by higher biomass (6.57 g/l) and pediocin [517.6 BU (bacteriocin activity units)/ml] concentrations compared with the batch processes on MRS (de Man, Rogosa and Sharpe) broth (1.76 g/l and 493.2 BU/ml), DW (0.17 g/l and 57.7 BU/ml), DWG (0.14 g/l and 53.6 BU/ml), DWYE (1.43 g/l and 187.6 BU/ml) and DWGYE (1.28 g/l and 167.3 BU/ml) media. A mixed acid fermentation was observed during the growth of P. acidilactici NRRL B-5627 in the fed-batch culture on DWYE medium, and other products (acetic acid and ethanol) in addition to lactic acid accumulated in the medium. Mathematical models were set up to describe fed-batch production of biomass and pediocin by P. acidilactici. The models developed offer a better fit and a more realistic description of the experimental biomass and pediocin production data when compared with the logistic and Luedeking and Piret model.

Development of a bioactive packaging cellophane using Nisaplin as biopreservative agent

AIMS

Production of a nisin-containing cellophane-based coating to be used in the packaging of chopped meat.

METHODS AND RESULTS

The adsorption of nisin to cellophane 'P' type surface was studied at 8, 25, 40 and 60 degrees C using different concentrations of nisin. Then, the antimicrobial activity of adsorbed nisin to cellophane surface was determined in fresh veal meat for effectiveness in reducing the total aerobic bacteria. The adsorption of nisin to cellophane was higher at 8 degrees C. The developed bioactive cellophane reduced significantly the growth of the total aerobic bacteria (by ca 1.5 log units) through 12 days of storage at 4 degrees C.

CONCLUSIONS

Bioactive cellophane packaging could be used for controlling the microbial growth in chopped meat.

SIGNIFICANCE AND IMPACT OF THE STUDY

Nisin-adsorbed bioactive cellophane would result in an extension of the shelf life of chopped meat under refrigeration temperatures.

Enhancement of nisin production by Lactococcus lactis in periodically re-alkalized cultures

Synthesis of nisin as well as biomass production by Lactococcus lactis subsp. lactis CECT (Colección Española de Cultivos Tipo) 539 on both hydrolysed mussel-processing waste and whey medium were followed in three fixed volume fed-batch fermentations, with re-alkalization cycles. The two cultures on mussel-processing waste (MPW) were fed with a 240 g/l concentrated glucose and with a concentrated MPW (about 100 g of glucose/l). The culture on whey was fed with a mixture of concentrated whey (48 g of total sugars/l) and a 400 g/l concentrated lactose. The three cultures were mainly characterized with higher nisin titres [49.7, 109.6 and 124.7 bacteriocin activity units (AU)/ml respectively] compared with the batch process on de Man, Rogosa and Sharpe [(1960) J. Appl. Bacteriol. 23, 130-135] medium (49.6 AU/ml), MPW (9.5 AU/ml) and whey (22.5 AU/ml) [1 AU/ml is the amount of antibacterial compound needed to obtain 50% growth inhibition (LD50) compared with control tubes]. In the three fed-batch cultures a shift from homolactic to mixed-acid fermentation was observed, and other products (acetic acid, butane-2,3-diol or ethanol) in addition to lactic acid were detectable in the medium. However, their contributions to the total antibacterial activity of the post-incubates (the cell-free culture supernatant obtained at the end of the fermentation process) of L. lactis CECT 539 against Carnobacterium piscicola CECT 4020 were very low.

Influence of pH drop on both nisin and pediocin production by Lactococcus lactis and Pediococcus acidilactici

AIMS

To develop a kinetic model for describing the specific effect of pH drop on nisin and pediocin production in whey.

METHODS AND RESULTS

The effect of pH drop on both bacteriocin productions was tested in non-buffered whey and whey buffered at initial pH 6.3 with 0.03, 0.10 and 0.25 mol l-1 of potassium hydrogen phthalate-NaOH. An accurate description of the experimental data of nisin and pediocin obtained at different pH drops is obtained with the proposed model.

CONCLUSIONS

The proposed model was able to typify both bacteriocins as pH-dependent primary metabolites.

SIGNIFICANCE AND IMPACT OF THE STUDY

The decisive role of pH drop for bacteriocin production on whey was demonstrated and modelled. This study contributes to a better understanding of underlying metabolic regulatory mechanisms, which could facilitate the optimization of bacteriocin production for upscaling.

Production of bacteriocins from Lactococcus lactis subsp. lactis CECT 539 and Pediococcus acidilactici NRRL B-5627 using mussel-processing wastes

The growth and bacteriocin production by Lactococcus lactis subsp. lactis CECT 539 and Pediococcus acidilactici NRRL B-5627 were investigated on mussel-processing wastes. Both bacteriocin productions were satisfactorily modelled using a modified form of the Luedeking and Piret expression, which includes a term for the influence of the pH reduction rate. Experimental data from cultures buffered at different initial concentrations (0, 0.03, 0.10 and 0.25 M) of both bacteria were used to fit and verify the model. The influence of total sugars, nitrogen, phosphorus and buffer concentration on nisin and pediocin production was also studied using response-surface methodology and empirical modelling. Enhanced nisin production (33 BU/ml) was achieved in media buffered with 0.10 M potassium hydrogen phthalate/NaOH. However, the highest levels of pediocin (368 BU/ml) were obtained in the non-buffered media.

Nisin and pediocin production on mussel-processing waste supplemented with glucose and five nitrogen sources

AIMS

Optimization of bacteriocin production by L. lactis subsp. lactis CECT 539 and Ped. acidilactici NRRL B-5627 on mussel-processing wastes.

METHODS AND RESULTS

The concentrations of glucose and five nitrogen sources that optimize nisin and pediocin production were determined using a second order orthogonal factorial design. NH4Cl, glycine and glutamic acid were poor nitrogen sources. Enhanced pediocin and nisin productions were achieved in a medium supplemented with yeast extract or Bacto casitone.

CONCLUSIONS

Mussel-processing wastes could be successfully used as a culture medium for bacteriocin production at low production cost.

SIGNIFICANCE AND IMPACT OF THE STUDY

Average optimization led to a threefold increase in pediocin production (from 322 to 934 BU ml(-1)) and in nisin production (from 32 to 100 BU ml(-1)) when compared with the unsupplemented medium. For this reason, mussel-processing waste warrants further investigation due to its potential use as a cheap culture medium for upscaling bacteriocin production.

Nutritional factors affecting the production of two bacteriocins from lactic acid bacteria on whey

The ability of Lactococcus lactis subsp. lactis CECT 539 and Pediococcus acidilactici NRRL B-5627 to produce bacteriocins on both diluted and concentrated whey was investigated in batch fermentations. Both strains produced the higher amounts of biomass and bacteriocin titres on diluted whey. Luedeking and Piret expression was able to model the production of nisin, which was produced as a primary metabolite on both culture media. However, the pediocin production could not be typified in any case due to the negligible growth of P. acidilactici. Although the whey supported the growth and bacteriocin production by the two strains, both biomass and bacteriocin productions were lower than those obtained on MRS broth. The effect of total sugar, nitrogen, phosphorous and buffer concentrations on the production of nisin and pediocin was studied in diluted whey using factorial experiments and empirical modelling. The production of nisin was greatly inhibited by the increase in nitrogen, buffer, and to a lesser extent, sugar concentration in the medium, nevertheless, the used phosphorous source produced a light stimulatory effect on bacteriocin synthesis. In addition, the growth of Lc 1.04 was mainly affected by the nitrogen source used. On the other hand, pediocin was inhibited by the increase in buffer, phosphorous, and to a lesser degree, by the sugar and nitrogen concentration. The inhibitory activity of pediocin disappeared almost totally after 15 min of treatment with trypsin, papain, subtilisin and pepsin. The activity of nisin was drastically reduced by treatment with trypsin, subtilisin and pepsin. Nevertheless, 50% of the initial activity was retained when nisin was treated with papain. Both bacteriocins showed the highest heat stability at acidic pH and short incubation times.