Bioprocess to valorise fleshing produced in the tanning industry

This study focuses on circular bioeconomy and how to reduce the management of solid by-products in tannery facilities. To achieve this, double enzymatic hydrolysis has been developed, which allows the integrated management of both limed and fresh fleshing that are classified as category 3 animal by-products (ABPs). Fleshing has an average content of 15% fat, 20% protein and 65% water. To process these components independently, the fat fraction is separated from the protein and liquid protein fractions. This bioprocess has been developed from fleshing, yielding up to 78% mass recovery as biostimulants that are suitable for formulation and use in the fertiliser market. The efficacy of the protein fraction as a biostimulant was validated through laboratory tests, specifically by cabbage germination, which exhibited a notable improvement by 25%.

Zero waste discharge in tannery industries - An achievable reality? A recent review

In the recent times, more attention is on industrial waste management due to the unaffordable space for dump yards and landfills and the increased charges for waste dumping. Even though the vegan revolution and plant-based meat products are booming, the traditional slaughterhouses and the wastes produced by them continue to be a concern. Waste valorisation is an established procedure striving to create a closed chain process in industries where there is no refuse. Although a highly polluting industry, slaughterhouse industry wastes have been recycled to economically viable leather since ancient times. However, the tannery industry is causing pollution in par with or even more than the slaughterhouses. Effective management of the liquid and solid wastes from the tannery is of utmost concern because of its toxicity. The hazardous wastes generated enter the food chain, causing long term impacts in the ecosystem. Several leather waste transformation processes are widely used in the industries, and they are yielding good products of economic value. However careful exploration into the processes and products of waste valorisation are often ignored as long as the transformed waste product is of higher value than the waste. The most efficient and environmentally friendly waste management technique should convert the refuse into a value-added utilization without any toxic leftovers. Zero waste concept is an extension of the zero liquid discharge concept, where the solid waste is also treated and reused to such an extent that there is no residue to be sent to the landfill. This review initially presents the existing methods for the de-toxification of tannery wastes and examines the possibility of solid waste management within the tannery industry to attain zero waste discharge.

Monitoring the curing efficiency of a plant-based green engineered additive on caprine skin: a spectroscopic and chemometric novel approach

Environmental sustainability in industrial processing is one of the most fundamental requirements for sustainable development. The leather industry is known for its vast environmental pollution. But, green engineering may occur a paradigm shift in this sector. Plant-based goatskins curing is a cutting-edge green technology that holds the concept of pollution reduction through prevention on the upper stream of leather processing. The successful and rapid monitoring of the efficiency of this technology is the foremost demand for mass-level applications. In this study, ATR-FTIR spectroscopy was employed to monitor this technology's efficiency using a plant Polygonum hydropiper. Chemometrics was also applied to extract information from spectral data leading to an understanding of the inherent effect of studying preservatives on goatskins collagen chemistry. 10% plant-paste +5% NaCl, 10% plant-paste +10% NaCl, and 15% plant-paste +5% NaCl on goatskin were assessed by ATR-FTIR on 0th, 10th, and 30th days of preservation. The Spectral peak fitting (R² = 0.99) area of amide I and II of collagen peptide bands revealed 2.73 to 1.33 times more structural suitability of studied goatskins than the control. Principal component analysis and Hierarchical cluster analysis showed that, after 30 days of curing, 15% paste +5% salt-rubbed goatskin collagen matrix significantly (around 50%) interacted with P. hydropiper. The interaction was superficial, as it happened before the opening up of collagen fibers. In conclusion, ATR-FTIR spectroscopy with Chemometrics can be an effective tool in evaluating the efficiency of goatskin curing and understanding the entire effect on collagen chemistry quickly.

Computational Modelling and Molecular Docking of Industrial Leather Enzymes

Leather is one of the widely traded commodities globally. It is a strategically important sector for the economic and industrial development of the country. However, the leather industry is perceived as a highly polluting industry. It produces huge amounts of solid and liquid wastes, and if these wastes are not properly treated and disposed of, then it tends to deteriorate the quality of soil and water, as well as cause emanations of smell and noxious gases into the surrounding. The current paper provides information about industrial leather enzymes, primarily collagenase, tannase, and lecithinase. In this study, enzymes such as collagenase, tannase, and lecithinase had a pivotal role in leather industries and their action in the bioremediation of leather effluents was further analysed and docked with a diverse range of compounds (ligands), with an optimal binding affinity score was determined. All interactions between protein ligands were depicted, which will help us with future research. Furthermore, this method can be tested practically, and other parameters can be studied in the future. Further, applications of enzymes and their hydrolyse by-products have also been highlighted in a variety of industries, including the pharmaceutical, cosmetic, agricultural, medical, and food sectors. Subsequently, this finding provides an innovative and broader goal for various sectors in terms of sustainability, stabilisation, and identifying research gaps that can guide modern industries and research scientists.

Current trends in solid tannery waste management

The tannery is one of the leading revenue-generating sectors in developing countries. The ever-increasing demand for leather products in the global market requires converting large amounts of rawhide/skins into resilient non-putrescible finished leather. Only 20% of the raw material is converted into a finished product; the rest 80% is discarded as solid and liquid wastes during leather processing. A heavy discharge of improperly treated solid tannery waste (STW) causes a severe impact on the surrounding environment by polluting soil, surface water, and groundwater resources, posing severe hazards to human and animal health. STW comprises proteinaceous untanned and tanned waste, which requires proper treatment for eco-friendly disposal. Several strategies have been developed over the years for the reduction and recycling of STW for producing renewable energy (biogas and biohydrogen), biofuels (biodiesel and briquettes), construction material, fertilizers, commercial products (adsorbents, animal feeds, proteins, fats, and enzymes), and biodegradable packaging and non-packaging materials. In this review, we discuss various strategies adopted for recycling, reutilization, and reduction of STW in an environment-friendly manner. Furthermore, an overview of the current perspectives toward achieving a zero-waste policy is also presented to reduce the environmental burden using green-clean technology to aid the survival of present-day tanneries.

Cleaner degreasing of sheepskins by the Yarrowia lipolytica LIP2 lipase as a chemical-free alternative in the leather industry

Conventional degreasing of skins and hides in the leather industry requires high amounts of organic solvents and detergents that cause environmental issues. In this study, the LIP2 lipase from the yeast Yarrowia lipolytica (YLLIP2) was shown to be effective in degreasing sheepskins, thus reducing the amount of harmful chemicals. Using 6 mg of lipase/kg of raw skin, successful degreasing was achieved in only 15 min at pH 8 and 30°C. ToF-SIMS mass spectra of chemically and enzymatically treated sheepskinsare consistent with a selective elimination process for the enzymatic treatment. Comparative SEM microscopy, ATR-FTIR spectroscopy and physicochemical analyses showed better properties of the enzymatically treated leather than those of the chemically treated leather. Effluent physicochemical parameters showed that the enzymatic treatment is a cleaner degreasing operation. Altogether, this work opens new horizons to use the YLLIP2 lipase as a more efficient alternative in the leather industry.

Detection and kinetic simulation of animal hair/wool wastes pyrolysis toward high-efficiency and sustainable management

Large quantities of solid wastes are produced each year in the leather industry. The considerable wastes generated exhibit tremendous application potential in terms of renewable energy sources and functional materials. Among them, animal hair/wool wastes possess high carbon content, which can be used sustainably and efficiently by using pyrolysis. Herein, the pyrolysis process of hair/wool wastes was investigated using TG-IR and Py-GC/MS, while the pyrolysis kinetic and thermodynamic were analyzed using "model-free" methods. The results showed that the hair/wool waste pyrolysis process can be divided into three stages: dehydration, devolatilization, and carbonization. The volatile products were mainly phenols (7.42%) and heterocyclic compounds (21.26%), which can be directly used as bio-energy (bio-gases and bio-oil) or converted to other useful chemical products. The kinetic parameters (E_a and A) calculated using the Flynn-Wall-Ozawa, Kissinger-Akahira-Sunose, and Kissinger methods indicated the complexity of the decomposition reactions, which was also confirmed by thermodynamic (ΔH, ΔG, and ΔS) calculation. Some suggestions have also been provided for the preparation of functional biochar with heteroatoms (i.e., N, O, and S) doping. These results not only provide a guide for designing the pyrolysis of hair/wool wastes but can also help develop a potential method to convert the hair/wool wastes into bioenergy to achieve sustainable development of the leather industry.

Keratinolytic protease from Pseudomonas aeruginosa for leather skin processing

Background

The leather industry generates huge volume of waste each year. Keratin is the principal constituents of this waste that is resistant to degradation. Some bacteria have the ability to degrade keratin through synthesis of a protease called keratinase that can be used as sources of animal feed and industrial production of biodiesel, biofertilizer, and bioplastic. Majority of the studies focused on keratin degradation using gram-positive bacteria. Not much of studies are currently available on production of keratinase from gram-negative bacteria and selection of best parameters for the maximum production of enzyme. The aim of this study was to isolate and characterize both groups of bacteria from soil for keratinase and optimize the production parameters.

Results

A total of 50 isolates were used for initial screening of enzyme production in skim milk, casein, and feather meal agar. Out of 50, five isolates showed significantly higher enzyme production in preliminary screening assays. Morphological and biochemical characterization revealed 60% of the isolates as gram-negative bacteria including two highest enzyme-producing isolates. The isolates were identified as Pseudomonas aeruginosa through sequencing of 16S rRNA gene. Maximum production of enzyme from P. aeruginosa YK17 was achieved with 2% chicken feather, beef extract, and ammonium nitrate as organic and inorganic nitrogen sources and glucose as a carbon source. Further analysis revealed that 3% inoculum, 40 °C growth temperature and 72-h incubation, resulted in maximum production of keratinase.

Conclusion

The overall results showed significant higher production of enzyme by the P. aeruginosa YK17 that can be used for the degradation of recalcitrant keratin waste and chemical dehairing in leather industries, thereby preventing environmental pollution.

Supplementary Information

The online version contains supplementary material available at 10.1186/s43141-021-00149-8.

Heterologous expression and purification of keratinase from Actinomadura viridilutea DZ50: feather biodegradation and animal hide dehairing bioprocesses

The keratin-degrading bacterium Actinomadura viridilutea DZ50 secretes a keratinase (KERDZ) with potential industrial interest. Here, the kerDZ gene was extracellularly expressed in Escherichia coli BL21(DE3)pLysS using pTrc99A vector. The recombinant enzyme (rKERDZ) was purified and biochemically characterized. Results showed that the native and recombinant keratinases have similar biochemical characteristics. The conventional dehairing with lime and sodium sulfide degrades the hair to the extent that it cannot be recovered. Thus, these chemical processes become a major contributor to wastewater problem and create a lot of environmental concern. The complete dehairing was achieved with 2000 U/mL rKERDZ for 10 h at 40 °C. In fact, keratinase assisted dehairing entirely degraded chicken feather (45 mg) and removed wool/hair from rabbit, sheep, goat, or bovine' hides (1.6 kg) while preserving the collagen structure. The enzymatic process is the eco-friendly option that reduces biological (BOD) (50%) and chemical (COD) oxygen demands (60%) in leather processing. Consequently, the enzymatic hair removal process could solve the problem of post-treatments encountering the traditional leather processing. The enzymatic (rKERDZ) dehaired leather was analyzed by scanning electron microscopic (SEM) studies, which revealed similar fiber orientation and compactness compared with control sample. Those properties support that the rKERDZ enzyme-mediated process is greener to some extent than the traditional one.

Evaluation of chromium accumulation and resulting histopathological changes in Libyan jirds (Mammals, Rodentia), affected by effluent from Ghazghan leather industrial town, Iran

The leather industry is one of the major producers of wastewater, releasing large amounts of various chemicals into the environment. Chromium (Cr) is the most commonly used agent in the tanning industry. Accumulation in the animal body can adversely affect the functioning of animal tissues. The current study investigated the toxic effects of Cr on lung, kidney, liver, and testicular tissues in Libyan jirds (Meriones libycus) inhabiting the area surrounding Ghazghan leather industrial town, Mashhad, Iran. Average Cr concentrations were found to be significantly higher in samples from contaminated areas than controls (p < 0.05). The highest accumulation of Cr was found in lung tissue, while the liver tissue showed the lowest. The results also showed that sex and age had no significant effect on Cr accumulation in any tissue at either sampling area (p < 0.05). Histological analyses showed that Cr accumulation had caused changes in tissue samples from Libyan jirds from the contaminated area. Hyperemia was observed in all tissues. In kidney tissue, necrosis and degeneration of the epithelial cells of the tubules were seen as well, and in one case, we also observed hemorrhage. In liver tissue, necrosis, degeneration, and inflammation were observed, along with one case, of fibrosis. In lung tissue, we observed emphysema, hemorrhage, and inflammation. Testicular tissue also showed a considerable lesion. Given the proximity of specimens' habitat to an area of importance, i.e., the industrial town, and the species' dependence on its habitat for nutrition, Libyan jirds are particularly useful for monitoring. Thus, they can be used to monitor the level of contamination in future studies.

Alternative tanning technologies and their suitability in curbing environmental pollution from the leather industry: A comprehensive review

Chrome tanning remains the most favourite technology in the leather industry worldwide due to its ability to produce leather with attributes desirable for high-quality leather such as excellent hydrothermal stability, better dyeing characteristics and softness. Nevertheless, the technology has been censured globally for its severe environmental detriments and adverse effects on human health and other organisms. Developing alternative eco-friendly tanning technologies capable of producing leather of high quality has remained a challenging scientific inquiry. This review article provides an assessment of various eco-friendly tanning attempts geared towards improving or replacing the chrome technology without compromising the quality of the produced leather. The reviewed publications have ascertained that, these attempts have been centred on recycling of spent liquors; chromium exhaustion enhancement and total replacement of chromium salts. The research gaps and levels of key environmental pollutants from the reviewed technologies are presented, and the qualities of the leather produced from these technologies are highlighted. Of all the examined alternative technologies, total replacement of chromium salts sounds ideal to elude adverse effects associated with chrome tanning. Combination tanning, which implies blending two tanning agents that individually cannot impart desired properties to the leather, is anticipated to be an alternative technology to chrome tanning. Apart from being an eco-friendly technology, combination tanning produces leather with similar features to those produced by chrome tanning. In this regard, blending vegetable tannins with aluminium sulphate provides a promising chrome-free tanning technology. However, further studies to optimize combination tanning technologies to suit industrial applications are highly recommended.

Improving characteristics of biochar produced from collagen-containing solid wastes based on protease application in leather production

Preparation of biochar from industrial solid wastes is receiving increasing attention in recent years. In this paper, alkaline protease, neutral protease and collagenolytic protease are used in preliminary steps of leather production, which are expected to replace the traditional chemical agents while preserving quality of the finished leather. The protease application has remarkable positive influence towards characteristics of biochar prepared by collagen-containing solid wastes produced in preliminary steps. The enzymatic action time should be more than 3 h for complete permeation and catalysis, and the diameters of treated collagen fibers were in the range of 10 to 20 nm. The micro-cracks occurring on collagen fibers would have an obviously impact on the formation of biochar. The application of proteases reduce the pollution of traditional production through replacing traditional polluted chemicals, and the characteristics of biochars are obviously improved with good surface area and high carbon content approximately 70%. Its surface area can reach 967 m²/g. These biochars contain oxygen-containing functional groups, and the oxygen content of biochars are all over 20%. The enzyme application in leather production are effective to the properties of biochars prepared by collagen-containing solid wastes. This research can serve as a basis for the preparation of biochar derived from of natural bio-wastes thereby promoting the development of biomaterials.

Wastewater from leather tanning and processing in Palestine: Characterization and management aspects

Leather manufacturing industry has major environmental impacts. Characterization of tannery's wastewater (WW) is a key step in the management of wastewater released from various processes. This study presents some physicochemical characteristics measured in wastewater. It compares the pollution loads released from both goat and cow hides processing. The main pollution characteristics of wastewater released from two local tanneries were determined experimentally, through analyzing real samples of industrial discharges. These include chemical oxygen demand (COD), total solids (TS), total dissolved solids (TDS), total suspended solids (TSS), pH, and the concentrations of chloride, ammonia (NH₃) and chromium in both states, Cr (III) and Cr (VI). Characterization of such processes effluents assists in identifying waste generation rates and discharges, and then in recommending cleaner production options. The results shows that the amount of WW produced in the local Palestinian tanneries is much lower than tanneries worldwide, whereas it is more concentrated with pollutants. Liming process has the highest COD and the highest pH value, where tanning process releases WW highly concentrated with chromium. Real process measurements and mass balance calculations indicated that the chromium uptake efficiency is only 46.6%. Such a low efficiency indicates that cleaner production measures are essential in local tanneries.

Removal of Fat Components in High TDS Leather Wastewater by Saline-Tolerant Lipase-Assisted Nanoporous-Activated Carbon

The present investigation was carried out for the degradation of fatty components in high TDS containing wastewater (soak liquor) discharged from leather industry, and the degradation was achieved by saline-tolerant lipase-immobilized functionalized nanoporous-activated carbon (STLNPAC). The lipase was extracted from the halophilic organism, Bacillus cereus. The optimum conditions for lipase production such as time, 60 h; temperature, 50 °C; pH, 10; and substrate concentration, 2.5% (w/v) were determined through response surface methodology (RSM). The functionalization of NPAC was done by ethylenediamine/glutaraldehyde covalent interaction technique followed by the immobilization of saline-tolerant lipase onto FNPAC. The functional properties of STLNPAC were analyzed through instrumentation techniques such as TGA-DSC, FT-IR, XRD, and SEM images. The lipid content of soak liquor was removed by > 99% at HRT of 60 min using STLNPAC-packed bed reactor. The efficiency was evaluated by using UV-visible and FT-IR spectroscopic analyses. The degradation of lipids was best obeyed by pseudo first-order rate kinetics, and the rate constant was found to be 1.6 × 10^-3 min^-1. The biodegradability index of soak liquor was increased from 0.322 to 0.426, highly favorable for the complete removal of organic components in subsequent operations.

Lime and Sulphide-Free Dehairing of Animal Skin Using Collagenase-Free Alkaline Protease from Vibrio metschnikovii NG155

The objective of this work was to isolate a microorganism producing alkaline protease that can be used as an ecofriendly alternative to chemicals in dehairing process of leather manufacture. Alkaline protease producing bacterium Vibrio metschnikovii NG155 was isolated from soil samples of leather industry. The protease was highly effective in dehairing of goat skin, completely eliminating the use of lime and sulfide. Histological studies of the skin after dehairing showed that the enzyme did not damage the collagen layer and brought good fiber opening. Absence of collagenase activity was confirmed by reacting pure collagen with the enzyme and analyzing it on SDS PAGE, which showed no degradation of collagen. The enzyme was stable in a wide range of pH (7-11) and temperature (10-50 °C), which makes it suitable for industrial application.