Synthesis of poly-(3-hydroxybutyrate-co-3-hydroxyvalerate) by recombinant Escherichia coli

Polyhydroxyalkanoate bio-production and its rise as biomaterial of the future

The first observation of a polyhydroxyalkanoate (PHA) aggregate was in 1888 by Beijenrinck. Despite polyhydroxybutyrate (PHB) being the first type of PHA discovered, it was not extracted and characterized until 1925 by Maurice Lemoigne in France, even before the concept of "macromolecules" was known. After more than 30 years, in 1958, Wilkinson and co-workers rediscovered PHB and its metabolic role in the cells as storage compound. PHB started to be appealing to the industry in the 1980s, when a few companies started to commercialize microbially produced PHAs. During the 1990 s, the focus was on reducing production costs to make PHA production economically feasible, for instance by genetically modified microorganisms and even plants. Since then, many advances have been made: diverse wastes as feedstock, different production processes, and tailored design of biopolymers. This paper summarizes the scientific and technological development of PHAs from their discovery in 1888 until their latest applications and current commercial uses. Future perspectives have been devised too based on the current bottlenecks.

Polyhydroxyalkanoates (PHAs): Biopolymers for Biofuel and Biorefineries

Fossil fuels are energy recourses that fulfill most of the world's energy requirements. However, their production and use cause severe health and environmental problems including global warming and pollution. Consequently, plant and animal-based fuels (also termed as biofuels), such as biogas, biodiesel, and many others, have been introduced as alternatives to fossil fuels. Despite the advantages of biofuels, such as being renewable, environmentally friendly, easy to source, and reducing the dependency on foreign oil, there are several drawbacks of using biofuels including high cost, and other factors discussed in the fuel vs. food debate. Therefore, it is imperative to produce novel biofuels while also developing suitable manufacturing processes that ease the aforementioned problems. Polyhydroxyalkanoates (PHAs) are structurally diverse microbial polyesters synthesized by numerous bacteria. Moreover, this structural diversity allows PHAs to readily undergo methyl esterification and to be used as biofuels, which further extends the application value of PHAs. PHA-based biofuels are similar to biodiesel except for having a high oxygen content and no nitrogen or sulfur. In this article, we review the microbial production of PHAs, biofuel production from PHAs, parameters affecting the production of fuel from PHAs, and PHAs biorefineries. In addition, future work on the production of biofuels from PHAs is also discussed.

Production of medium chain length polyhydroxyalkanoate in metabolic flux optimized Pseudomonas putida

BACKGROUND

Pseudomnas putida is a natural producer of medium chain length polyhydroxyalkanoates (mcl-PHA), a polymeric precursor of bioplastics. A two-fold increase of mcl-PHA production via inactivation of the glucose dehydrogenase gene gcd, limiting the metabolic flux towards side products like gluconate was achieved before. Here, we investigated the overproduction of enzymes catalyzing limiting steps of mcl-PHA precursor formation.

RESULTS

A genome-based in silico model for P. putida KT2440 metabolism was employed to identify potential genetic targets to be engineered for the improvement of mcl-PHA production using glucose as sole carbon source. Here, overproduction of pyruvate dehydrogenase subunit AcoA in the P. putida KT2440 wild type and the Δgcd mutant strains led to an increase of PHA production. In controlled bioreactor batch fermentations PHA production was increased by 33% in the acoA overexpressing wild type and 121% in the acoA overexpressing Δgcd strain in comparison to P. putida KT2440. Overexpression of pgl-encoding 6-phosphoglucolactonase did not influence PHA production. Transcriptome analyses of engineered PHA producing P. putida in comparison to its parental strains revealed the induction of genes encoding glucose 6-phosphate dehydrogenase and pyruvate dehydrogenase. In addition, NADPH seems to be quantitatively consumed for efficient PHA synthesis, since a direct relationship between low levels of NADPH and high concentrations of the biopolymer were observed. In contrast, intracellular levels of NADH were found increased in PHA producing organisms.

CONCLUSION

Production of mcl-PHAs was enhanced in P. putida when grown on glucose via overproduction of a pyruvate dehydrogenase subunit (AcoA) in combination with a deletion of the glucose dehydrogenase (gcd) gene as predicted by in silico elementary flux mode analysis.

Bioplastics science from a policy vantage point

Society is fundamentally ambivalent to the use of plastics. On the one hand, plastics are uniquely flexible materials that have seen them occupy a huge range of functions, from simple packing materials to complex engineering components. On the other hand, their durability has raised concerns about their end-of-life disposal. When that disposal route is landfill, their invulnerability to microbial decomposition, combined with relatively low density and high bulk, means that plastics will occupy increasing amounts of landfill space in a world where available suitable landfill sites is shrinking. The search for biodegradable plastics and their introduction to the marketplace would appear to be a suitable amelioration strategy for such a problem. And yet the uptake of biodegradable plastics has been slow. The term biodegradable itself has entered public controversy, with accidental and intended misuse of the term; the intended misuse has led to accusations and instances of 'greenwashing'. For this and other reasons standards for biodegradability and compostability testing of plastics have been sought. An environmental dilemma with more far-reaching implications is climate change. The need for rapid and deep greenhouse gas (GHG) emissions cuts is one of the drivers for the resurgence of industrial biotechnology generally, and the search for bio-based plastics more specifically. Bio-based has come to mean plastics based on renewable resources, but this need not necessarily imply biodegradability. If the primary purpose is GHG emissions savings, then once again plastics durability can be a virtue, if the end-of-life solution can be energy recovery during incineration or recycling. The pattern of production is shifting from the true biodegradable plastics to the bio-based plastics, and that trend is likely to persist into the future. This paper looks at aspects of the science of biodegradable and bio-based plastics from the perspective of policy advisers and makers. It is often said that the bioplastics suffer from a lack of a favourable policy regime when compared to the wide-ranging set of policy instruments that are available on both the supply and demand side of biofuels production. Some possible policy measures are discussed.

Synthetic biology: an emerging research field in China

Synthetic biology is considered as an emerging research field that will bring new opportunities to biotechnology. There is an expectation that synthetic biology will not only enhance knowledge in basic science, but will also have great potential for practical applications. Synthetic biology is still in an early developmental stage in China. We provide here a review of current Chinese research activities in synthetic biology and its different subfields, such as research on genetic circuits, minimal genomes, chemical synthetic biology, protocells and DNA synthesis, using literature reviews and personal communications with Chinese researchers. To meet the increasing demand for a sustainable development, research on genetic circuits to harness biomass is the most pursed research within Chinese researchers. The environmental concerns are driven force of research on the genetic circuits for bioremediation. The research on minimal genomes is carried on identifying the smallest number of genomes needed for engineering minimal cell factories and research on chemical synthetic biology is focused on artificial proteins and expanded genetic code. The research on protocells is more in combination with the research on molecular-scale motors. The research on DNA synthesis and its commercialisation are also reviewed. As for the perspective on potential future Chinese R&D activities, it will be discussed based on the research capacity and governmental policy.

Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) co-polymer production from a local isolate, Brevibacillus invocatus MTCC 9039

Accumulation of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) [P(3HB-co-3HV)] co-polymer by a local isolate, Brevibacillus invocatus MTCC 9039 under batch mode was investigated under glucose, acetate and propionate-supplemented conditions. Cells harvested at the stationary phase of growth depicted maximum accumulation of poly-3-hydroxybutyrate (PHB), i.e. 3% of dry cell weight (dcw) at pH 7.0 and temperature 30 degrees C at 48h of incubation. PHB accumulation reached up to 52% (dcw) under 3% glucose with 1% acetate supplementation. P(3HB-co-3HV) co-polymer synthesis was observed under propionate-supplemented condition, which reached up to 45% under 3% glucose with 1% propionate supplementation. Optimization of process parameters by response surface methodology (RSM) resulted into co-polymer accumulation up to 65% (dcw) at 2.08% glucose, 1.62% acetate, 0.75% propionate and 2.15 g l(-1) KH(2)PO(4) concentrations. This co-polymer exhibited comparable material properties with the commercial [P(3HB-co-3HV)] co-polymers, whereas the elasticity was tremendously high and could be comparable with polypropylene. Thus, B. invocatus MTCC 9039 is emerging as an interesting organism and could be exploited further for P(3HB-co-3HV) co-polymer production.

Biosynthesis of novel terpolymers poly(lactate-co-3-hydroxybutyrate-co-3-hydroxyvalerate)s in lactate-overproducing mutant Escherichia coli JW0885 by feeding propionate as a precursor of 3-hydroxyvalerate

Novel lactate (LA)-based terpolymers, P[LA-co-3-hydroxybutyrate(3HB)-co-3-hydroxyvalerate(3HV)]s (PLBVs), were produced in LA-overproducing mutant, Escherichia coli JW0885, which was found to be a superior host for the efficient production of LA-based polyesters. Recombinant E. coli JW0885 harboring the genes encoding LA-polymerizing enzyme (Ser325Thr/Gln481Lys mutant of polyhydroxyalkanoate synthase from Pseudomonas sp. 61-3) and three monomer supplying enzymes [propionyl-CoA transferase, beta-ketothiolase, and nicotinamide adenine dinucleotide phosphate (reduced form) (NADPH)-dependent acetoacetyl-CoA reductase] was aerobically grown on glucose with feeding of propionate as a precursor of 3-hydroxyvaleryl-CoA (3HV-CoA). Gas chromatography and nuclear magnetic resonance (NMR) analyses revealed that polymers accumulated in the cells were composed of LA, 3HB, and 3HV units, thus being identified as terpolymers, PLBVs. In addition, (1)H-NMR analysis suggested the existence of LA-3HV sequence in the terpolymer. When 100 mg/l of sodium propionate was added into the medium, 3HV fraction in the terpolymer linearly reached up to 7.2 mol%, while LA fraction was inversely decreased. This phenomenon could be due to the change in metabolic fluxes of lactyl-CoA (LA-CoA) and 3HV-CoA depending on the concentration of propionate fed into the medium.

Engineering poly(3-hydroxybutyrate-co-3-hydroxyvalerate) copolymer composition inE. coli

A strain of Escherichia coli was metabolically engineered to produce poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) of specified composition between 5% and 18% HV. A gene encoding propionyl-CoA synthetase (prpE from S. enterica) was placed under the control of the IPTG-inducible tac promoter (P(taclacUV5)) while the polyhydroxyalkanoate synthesis operon (phaBCA) from R. eutropha was expressed constitutively. A strain of E. coli harboring both plasmids was grown in defined medium and PHBV was produced with specified hydroxyvalerate (HV) molar content between 5% and 18%. The molecular weight of the copolymer was approximately 700,000 across various HV contents, and average polydispersity was approximately 1.3. The majority of the PHBV production occurred during the late exponential/stationary phase. The HV content of the copolymer generally peaked early in the incubation before falling to its final value. We found that the time profiles of PrpE activity, propionyl-CoA, and acetyl-CoA were well correlated to the HV content time profile. Despite an abundance of propionyl-CoA, incorporation of HV into the copolymer was inefficient. Therefore, both the PHA operon and conditions affecting the availability of propionyl-CoA must be chosen carefully to achieve the desired HV content. The ability to engineer copolymer composition control into an E. coli strain would be useful in cases where the feedstock composition is not adjustable.

Recent Advances in Polyhydroxyalkanoate Production by Mixed Aerobic Cultures: From the Substrate to the Final Product

Numerous bacteria have been found to exhibit the capacity for intracellular polyhydroxyalkanoates (PHA) accumulation. Current methods for PHA production at the industrial scale are based on their synthesis from microbial isolates in either their wild form or by recombinant strains. High production costs are associated with these methods; thus, attempts have been made to develop more cost-effective processes. Reducing the cost of the carbon substrates (e.g., through feeding renewable wastes) and increasing the efficiency of production technologies (including both fermentation and downstream extraction and recovery) are two such examples of these attempts. PHA production processes based on mixed microbial cultures are being investigated as a possible technology to decrease production costs, since no sterilization is required and bacteria can adapt quite well to the complex substrates that may be present in waste material. PHA accumulation by mixed cultures has been found under various operational conditions and configurations at both bench-scale and full-scale production. The process known as "feast and famine" or as "aerobic dynamic feeding" seems to have a high potential for PHA production by mixed cultures. Enriched cultures submitted to a transient carbon supply can synthesize PHA at levels comparable to those of pure cultures. Indeed, the intracellular PHA content can reach around 70% of the cell dry weight, suggesting that this process could be competitive with pure culture PHA production when fully developed. Basic and applied research of the PHA production process by mixed cultures has been carried out in the past decade, focusing on areas such as microbial characterization, process configuration, reactor operational strategies, process modeling and control, and polymer characterization. This paper presents a review of the PHA production process with mixed cultures, encompassing the findings reported in the literature as well as our own experimental results in relation to each of these areas.

Sequential feeding of glucose and valerate in a fed-batch culture of Ralstonia eutropha for production of poly(hydroxybutyrate-co-hydroxyvalerate) with high 3-hydroxyvalerate fraction

Several important properties of poly(3-hydroxybutyric-co-3-hydroxyvaleric acids) (P(3HB-co-3HV) depend mainly on the HV unit fraction of the copolymer. Sequential and simultaneous feeding of glucose and valerate were employed to produce P(3HB-co-3HV) in a fed-batch culture of Ralstonia eutropha, and the effects of feeding models on the cell growth, 3HV unit fraction, and copolymer productivity have been investigated. The sequential feeding of glucose and then valerate resulted in a cell density of 110.2 g/L, 3HV unit fraction of 62.7 mol %, and copolymer productivity of 0.56 g/(L.h), while the latter simultaneous feeding strategy never achieved the 3HV fraction of P(3HB-co-3HV) higher than 50%. A nuclear magnetic resonance study confirmed that the production of random copolymer P(3HB-co-3HV) with high 3HV unit fraction was possible even with sequential feeding of glucose and valerate.

Production of microbial polyester by fermentation of recombinant microorganisms

Polyhydroxyalkanoates (PHAs) can be produced from renewable sources and are biodegradable with similar material properties and processibility to conventional plastic materials. With recent advances in our understanding of the biochemistry and genetics of PHA biosynthesis and cloning of the PHA biosynthesis genes from a number of different bacteria, many different recombinant bacteria have been developed to improve PHA production for commercial applications. For enhancing PHA synthetic capacity, homologous or heterologous expression of the PHA biosynthetic enzymes has been attempted. Several genes that allow utilization of various substrates were transformed into PHA producers, or non-PHA producers utilizing inexpensive carbon substrate were transformed with the PHA biosynthesis genes. Novel PHAs have been synthesized by introducing a new PHA biosynthesis pathway or a new PHA synthase gene. In this article, recent advances in the production of PHA by recombinant bacteria are described.

High-level production of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) by fed-batch culture of recombinant Escherichia coli

Fermentation strategies for production of high concentrations of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) [P(3HB-co-3HV)] with different 3-hydroxyvalerate (3HV) fractions by recombinant Escherichia coli harboring the Alcaligenes latus polyhydroxyalkanoate biosynthesis genes were developed. Fed-batch cultures of recombinant E. coli with the pH-stat feeding strategy facilitated production of high concentrations and high contents of P(3HB-co-3HV) in a chemically defined medium. When a feeding solution was added in order to increase the glucose and propionic acid concentrations to 20 g/liter and 20 mM, respectively, after each feeding, a cell dry weight of 120.3 g/liter and a relatively low P(3HB-co-3HV) content, 42.5 wt%, were obtained. Accumulation of a high residual concentration of propionic acid in the medium was the reason for the low P(3HB-co-3HV) content. An acetic acid induction strategy was used to stimulate the uptake and utilization of propionic acid. When a fed-batch culture and this strategy were used, we obtained a cell concentration, a P(3HB-co-3HV) concentration, a P(3HB-co-3HV) content, and a 3HV fraction of 141.9 g/liter, 88.1 g/liter, 62.1 wt%, and 15.3 mol%, respectively. When an improved nutrient feeding strategy, acetic acid induction, and oleic acid supplementation were used, we obtained a cell concentration, a P(3HB-co-3HV) concentration, a P(3HB-co-3HV) content, and a 3HV fraction of 203.1 g/liter, 158.8 g/liter, 78.2 wt%, and 10.6 mol%, respectively; this resulted in a high level of productivity, 2.88 g of P(3HB-co-3HV)/liter-h.

Metabolic engineering of poly(3-hydroxyalkanoates): from DNA to plastic

Poly(3-hydroxyalkanoates) (PHAs) are a class of microbially produced polyesters that have potential applications as conventional plastics, specifically thermoplastic elastomers. A wealth of biological diversity in PHA formation exists, with at least 100 different PHA constituents and at least five different dedicated PHA biosynthetic pathways. This diversity, in combination with classical microbial physiology and modern molecular biology, has now opened up this area for genetic and metabolic engineering to develop optimal PHA-producing organisms. Commercial processes for PHA production were initially developed by W. R. Grace in the 1960s and later developed by Imperial Chemical Industries, Ltd., in the United Kingdom in the 1970s and 1980s. Since the early 1990s, Metabolix Inc. and Monsanto have been the driving forces behind the commercial exploitation of PHA polymers in the United States. The gram-negative bacterium Ralstonia eutropha, formerly known as Alcaligenes eutrophus, has generally been used as the production organism of choice, and intracellular accumulation of PHA of over 90% of the cell dry weight have been reported. The advent of molecular biological techniques and a developing environmental awareness initiated a renewed scientific interest in PHAs, and the biosynthetic machinery for PHA metabolism has been studied in great detail over the last two decades. Because the structure and monomeric composition of PHAs determine the applications for each type of polymer, a variety of polymers have been synthesized by cofeeding of various substrates or by metabolic engineering of the production organism. Classical microbiology and modern molecular bacterial physiology have been brought together to decipher the intricacies of PHA metabolism both for production purposes and for the unraveling of the natural role of PHAs. This review provides an overview of the different PHA biosynthetic systems and their genetic background, followed by a detailed summation of how this natural diversity is being used to develop commercially attractive, recombinant processes for the large-scale production of PHAs.