Application of the biorefinery concept to produce L-lactic acid from the soybean vinasse at laboratory and pilot scale

Current postbiotics in the cosmetic market-an update and development opportunities

Postbiotics are a new class of health-promoting molecules that derive from probiotics. These new cosmetic and dermatological ingredients are defined as a 'preparation of inanimate microorganisms and/or their components that confers a health benefit on the host'. This review focuses on what is presently known of these compounds, the benefits of using them, the main postbiotics products available in the market and players, the production key trends and available production methods. The main advantages identified for the use of postbiotics are related to their higher specificity of action on resident microbiota as of interaction with cells of the host compared to probiotics. Postbiotics can be produced/obtained especially through fermentative processes, but most of companies industrial processes are patented. Most of these compounds are usually derived from lactic acid bacteria, Lactobacillus genera and/or yeasts, especially Saccharomyces cerevisiae. Postbiotics go from metabolites like teichoic acids to polysaccharides among others and exhibit important biological properties such as antioxidant, anti-inflammatory, anti-proliferative and immunomodulatory-the reason why their use in cosmetic formulations must be considered. Besides that, when compared to probiotics, postbiotics have longer shelf life and greater safety and do not require viability in the topical formulation which turns them into an innovative approach within the cosmetic ingredients market. The main players are companies that operate in several areas, such as the chemical industry, food innovation, pharmaceutical and cosmetic industries, and the critical trends for production of these compounds include energy efficiency, emission-free mobility, conservation of finite resources and renewable raw material utilization. KEY POINTS: • Postbiotics are mainly derived from lactic acid bacteria and S. cerevisiae. • Postbiotics exhibit several biological properties. • Postbiotics present several advantages over probiotics.

Upscale fermenter design for lactic acid production from cheese whey permeate focusing on impeller selection and energy optimization

This study focusses on the design and scale-up of industrial lactic acid production by fermentation of dairy cheese whey permeate based on standard methodological parameters. The aim was to address the shortcomings of standard scale-up methodologies and provide a framework for fermenter scale-up that enables the accurate estimation of energy consumption by suitable selection of turbine and speed for industrial deployment. Moreover, life cycle assessment (LCA) was carried out to identify the potential impacts and possibilities to reduce the operation associated emissions at an early stage. The findings showed that a 3000 times scale-up strategy assuming constant geometric dimensions and specific energy consumption (P/V_w) resulted in lower impeller speed and energy demand. The Rushton turbine blade (RTB) and LightninA315 four-blade hydrofoil (LA315) were found to have the highest and lowest torque output, respectively, at a similar P/V_w of 2.8 kWm⁻³, with agitation speeds of 1.33 and 2.5 s⁻¹, respectively. RTB demonstrating lower shear damage towards cells (up to 1.33 s⁻¹) was selected because it permits high torque, low-power and acceptable turbulence. The LCA results showed a strong relation between the number of impellers installed and associated emissions suggesting a trade-off between mixing performance and environmental impacts.

R, Maitra S, Tarafdar A, Alphy MP, Kumar AN, Madhavan A, Sirohi R, Awasthi MK, Sindhu R, Varjani S, Binod P. Waste-Derived Fuels and Renewable Chemicals for Bioeconomy Promotion: A Sustainable Approach

Bio-based fuels and chemicals through the biorefinery approach has gained significant interest as an alternative platform for the petroleum-derived processes as these biobased processes are noticed to have positive environmental and societal impacts. Decades of research was involved in understanding the diversity of microorganisms in different habitats that could synthesize various secondary metabolites that have functional potential as fuels, chemicals, nutraceuticals, food ingredients, and many more. Later, due to the substrate-related process economics, the diverse low-value, high-carbon feedstocks like lignocellulosic biomass, industrial byproducts, and waste streams were investigated to have greater potential. Among them, municipal solid wastes can be used as the source of substrates for the production of commercially viable gaseous and liquid fuels, as well as short-chain fattyacids and carboxylic acids. In this work, technologies and processes demanding the production of value-added products were explained in detail to understand and inculcate the value of municipal solid wastes and the economy, and it can provide to the biorefinery aspect.

Identification of Cooperative Reaction Sites in Metal-Organic Framework Catalysts for High Yielding Lactic Acid Production from d-Xylose

Determining the roles of surface functionality of heterogeneous acid catalysts is important for many industrial catalysts. In this study, the decisive structure of metal-organic frameworks (MOFs) is utilized to identify important features for the effective conversion of d-xylose into lactic acid. Several acidic MOFs are tested and the combination of Lewis acidity and adjacent hydroxy sites is found to be critical to attain high lactic acid yields. This hypothesis is corroborated experimentally by modification of the MOF to increase such sites, which affords an enhanced lactic acid yield of 79 %, and investigation of the acidity by using in situ FTIR spectroscopy. Density functional theory calculations disclose the cooperative behavior of Lewis acid sites and hydroxy groups in promoting the Cannizzaro reaction, a key step in the production of lactic acid.

Microbial α-galactosidases: Efficient biocatalysts for bioprocess technology

Galactomannans, abundantly present in plant biomass, can be used as renewable fermentation feedstock for biorefineries working for the production of bioethanol and other value-added products. The complete and efficient bioconversion of biomass to fermentable sugars for the generation of biofuels and other value-added products require the concerted action of accessory enzymes like α-galactosidases, which can work in cohesion with other carbohydrases in an enzyme cocktail. In the paper industry, α-galactosidases enhance the bleaching effect of endo-β-1,4-mannanases on softwood kraft pulp. Microbial α-galactosidases also find applications in the treatment of legume foods, recovery of sucrose from sugar beet syrup, improving the rheological properties of galactomannans, and synthesis of α-galactooligosaccharides to be used as functional food ingredients. Owing to their industrial applications, there is a surge in the research focused on α-galactosidases. The current review illustrates the diverse industrial applications of microbial α-galactosidases and their challenges and prospects.

Designing enzyme cocktails from Penicillium and Aspergillus species for the enhanced saccharification of agro-industrial wastes

The aim of this study was to develop optimized enzyme cocktails, containing native and recombinant purified enzymes from five fungal species, for the saccharification of alkali- and acid-pretreated sugarcane bagasse (SCB), soybean hulls (SBH) and oil palm empty fruit bunches (EFB). Basic cellulases were represented by cellobiohydrolase I (CBH) and endo-glucanase II (EG) from Penicillium verruculosum and β-glucosidase (BG) from Aspergillus niger. Auxiliary enzymes were represented by endo-xylanase A (Xyl), pectin lyase (PNL) and arabinoxylanhydrolase (AXH) from Penicillium canescens, β-xylosidase (BX) from Aspergillus japonicus, endo-arabinase (ABN) from A. niger and arabinofuranosidase (Abf) from Aspergillus foetidus. Enzyme loads were 5 mg protein/g dry substrate (basic cellulases) and 1 mg/g (each auxiliary enzyme). The best choice for SCB and EFB saccharification was alkaline pretreatment and addition of Xyl + BX, AXH + BX or ABN + BX + Abf to basic cellulases. For SBH, acid pretreatment and basic cellulases combined with ABN + BX + Abf or Xyl + BX performed better than other enzyme preparations.

Effect of Novel Penicillium verruculosum Enzyme Preparations on the Saccharification of Acid- and Alkali-Pretreated Agro-Industrial Residues

This study aimed at evaluating different enzyme combinations in the saccharification of sugarcane bagasse (SCB), soybean husks (SBH) and oil palm empty fruit bunches (EFB) submitted to mild acid and alkaline pretreatments. Enzyme pools were represented by B1 host (crude cellulase/xylanase complexes of Penicillium verruculosum); B1-XylA (Penicillium canescens xylanase A expressed in P. verruculosum B1 host strain); and F10 (Aspergillus niger β-glucosidase expressed in B1 host strain). Enzyme loading was 10 mg protein/g dry substrate and 40 U/g of β-glucosidase (F10) activity. SCB was efficiently hydrolyzed by B1 host after alkaline pretreatment, yielding glucose and reducing sugars at 71 g/L or 65 g/100 g of dry pretreated substrate and 91 g/L or 83 g/100 g, respectively. B1 host performed better also for EFB, regardless of the pretreatment method, but yields were lower (glucose 27–30 g/L, 25–27 g/100 g; reducing sugars 37–42 g/L, 34–38 g/100 g). SBH was efficiently saccharified by the combination of B1 host and B1-XylA, yielding similar concentrations of reducing sugars for both pretreatments (92–96 g/L, 84–87 g/100 g); glucose recovery, however, was higher with alkaline pretreatment (81 g/L, 74 g/100 g). Glucose and reducing sugar yields from initial substrate mass were 42% and 54% for SCB, 36% and 42–47% for SBH and 16–18% and 21–26% for EFB, respectively.

Membrane Technologies for Lactic Acid Separation from Fermentation Broths Derived from Renewable Resources

Lactic acid (LA) was produced on a pilot scale using a defined medium with glucose, acid whey, sugar bread and crust bread. The fermentation broths were then subjected to micro- and nanofiltration. Microfiltration efficiently separated the microbial cells. The highest average permeate flow flux was achieved for the defined medium (263.3 L/m²/h) and the lowest for the crust bread-based medium (103.8 L/m²/h). No LA losses were observed during microfiltration of the acid whey, whilst the highest retention of LA was 21.5% for crust bread. Nanofiltration led to high rejections of residual sugars, proteins and ions (sulphate, magnesium, calcium), with a low retention of LA. Unconverted sugar rejections were 100% and 63% for crust bread and sugar bread media respectively, with corresponding LA losses of 22.4% and 2.5%. The membrane retained more than 50% of the ions and proteins present in all media and more than 60% of phosphorus. The average flux was highly affected by the nature of the medium as well as by the final concentration of LA and sugars. The results of this study indicate that micro- and nanofiltration could be industrially employed as primary separation steps for the biotechnologically produced LA.

Semi-continuous production of high-activity pectinases by immobilized Rhizopus oryzae using tobacco wastewater as substrate and their utilization in the hydrolysis of pectin-containing lignocellulosic biomass at high solid content

In this study, highly reactive endo- and exo-polygalacturonases (PGs) were produced from the tobacco industry wastewater using immobilized Rhizopus oryzae. Compared with free cells, immobilized cells increased enzyme activity 2.8-fold and reduced production time to 24h by shake-flask production. Moreover, the immobilized cells enabled the semi-continuous production of enzymes through repeated-batch mode for seven consecutive cycles in a scale-up bioreactor. During the first five cycles, the average endo-PG and exo-PG activities reached 307.5 and 242.6U/ml, respectively. The addition of crude enzyme for the hydrolysis of pectin-containing lignocellulosic biomass under high-gravity conditions increased glucose release 4.2-fold (115.4 vs. 29.0g/L), compared with hydrolysis using cellulase alone. This process achieves the efficient production of pectin-degrading enzymes, provides a cost-effective method for tobacco wastewater treatment, and offers the possibility to obtain fermentable sugars with high-titer from pectin-containing lignocellulosic biomass, which has important potential for the commercial production of bio-fuels.

Enzyme recycle and fed-batch addition for high-productivity soybean flour processing to produce enriched soy protein and concentrated hydrolysate of fermentable sugars

Despite having high protein and carbohydrate, soybean flour utilization is limited to partial replacement of animal feed to date. Enzymatic process can be exploited to increase its value by enriching protein content and separating carbohydrate for utilization as fermentation feedstock. Enzyme hydrolysis with fed-batch and recycle designs were evaluated here for achieving this goal with high productivities. Fed-batch process improved carbohydrate conversion, particularly at high substrate loadings of 250-375g/L. In recycle process, hydrolysate retained a significant portion of the limiting enzyme α-galactosidase to accelerate carbohydrate monomerization rate. At single-pass retention time of 6h and recycle rate of 62.5%, reducing sugar concentration reached up to 120g/L using 4ml/g enzyme. When compared with batch and fed-batch processes, the recycle process increased the volumetric productivity of reducing sugar by 36% (vs. fed-batch) to 57% (vs. batch) and that of protein product by 280% (vs. fed-batch) to 300% (vs. batch).

Using slaughterhouse waste in a biochemical-based biorefinery - results from pilot scale tests

A novel biorefinery concept was piloted using protein-rich slaughterhouse waste, chicken manure and straw as feedstocks. The basic idea was to provide a proof of concept for the production of platform chemicals and biofuels from organic waste materials at non-septic conditions. The desired biochemical routes were 2,3-butanediol and acetone-butanol fermentation. The results showed that hydrolysis resulted only in low amounts of easily degradable carbohydrates. However, amino acids released from the protein-rich slaughterhouse waste were utilized and fermented by the bacteria in the process. Product formation was directed towards acidogenic compounds rather than solventogenic products due to increasing pH-value affected by ammonia release during amino acid fermentation. Hence, the process was not effective for 2,3-butanediol production, whereas butyrate, propionate, γ-aminobutyrate and valerate were predominantly produced. This offered fast means for converting tedious protein-rich waste mixtures into utilizable chemical goods. Furthermore, the residual liquid from the bioreactor showed significantly higher biogas production potential than the corresponding substrates. The combination of the biorefinery approach to produce chemicals and biofuels with anaerobic digestion of the residues to recover energy in form of methane and nutrients that can be utilized for animal feed production could be a feasible concept for organic waste utilization.

Using tobacco waste extract in pre-culture medium to improve xylose utilization for l-lactic acid production from cellulosic waste by Rhizopus oryzae

The aim of this work was to study the high-titer l-lactic acid production from cellulosic waste using Rhizopus oryzae. The tobacco waste water-extract (TWE) added with 5g/L glucose and 0.1g/L vitamin C was optimized as pre-culture medium for R. oryzae. Results found that compared to traditional pre-culture medium, it improved xylose consumption rate up to 2.12-fold and enhanced l-lactic acid yield up to 1.73-fold. The highest l-lactic acid concentration achieved was 173.5g/L, corresponding to volumetric productivity of 1.45g/Lh and yield of 0.860g/g total reducing sugar in fed-batch fermentation. This process achieves efficient production of polymer-grade l-lactic acid from cellulosic feedstocks, lowers the cost of fungal cell pre-culture and provides a novel way for re-utilization of tobacco waste.

Highly efficient l-lactic acid production from xylose in cell recycle continuous fermentation using Enterococcus mundtii QU 25

We report an effective cell recycling continuous fermentation of xylose to l-lactic acid with high concentration, productivity, and yield using strain QU 25. pH was found to affect the yield and corn steep liquor as feeding medium enhanced the yield.

Efficiency of physicochemical and biological treatments of vinasse and their influence on indigenous microbiota for disposal into the environment

Molasses-based distilleries are one of the most polluting industries generating large volumes of high strength wastewater called vinasse. Different processes covering anaerobic, aerobic as well as physicochemical methods have been employed to treat this effluent. This study evaluated the microbial communities present in the vinasse during different stages of its treatment by traditional and molecular methods. The analysis of the efficiency of each treatment was performed by physicochemical parameters and toxicity analysis. The treatment of vinasse was performed in the following steps: high flow fermentation; filtration; chemical flakes; low-flow fermentation; filtration; and neutralization. The physicochemical analysis in different stages of the vinasse treatment demonstrated that phases of treatment influenced the performance of the evaluated parameters. Among the 37 parameters, 9 were within the limits established by the Commission for Environmental Policy of Minas Gerais, Brazil (COPAM), especially BOD (96.7% of pollution reduction), suspended solids (99.9%), pH, copper (88%), iron (92.9%), and manganese (88%). Some parameters, even after treatment, did not fit the maximum allowed by legislation. The microbial population decreased reaching 3 log CFU/ml present in the steps of the flakes chemical and disinfection treatment of vinasse. Lactobacillus brevis and Pichia kudriavzevii were present in all stages of the treatments, showing that these microorganisms were resistant and demonstrated that they might be important in the treatment of vinasse. The vinasse showed a significant reduction of pollution load after the disinfection treatment however still should not be discarded into water bodies because the high values of tannins and sediment solids, but suggest the use of the effluent in the cooling coil during the distillation process of the beverage.

Engineering and adaptive evolution of Escherichia coli W for L-lactic acid fermentation from molasses and corn steep liquor without additional nutrients

The D-lactic acid producing strain, Escherichia coli HBUT-D, was reengineered for L(+)-lactic acid fermentation by replacing the D-lactate dehydrogenase gene (ldhA) with an L(+)-lactate dehydrogenase gene (ldhL) from Pedicoccus acidilactici, followed by adaptive evolution in sucrose. The resulting strain, WYZ-L, has enhanced expression of the sucrose operon (cscA and cscKB). In 100 g L(-1) of sucrose fermentation using mineral salt medium, WYZ-L produced 97 g L(-1) of l(+)-lactic acid, with a yield of 90%, a maximum productivity of 3.17 g L(-1)h(-1) and an optical purity of greater than 99%. In fermentations using sugarcane molasses and corn steep liquor without additional nutrients, WYZ-L produced 75 g L(-1) of l(+)-lactic acid, with a yield of 85%, a maximum productivity of 1.18 g L(-1)h(-1), and greater than 99% optical purity. These results demonstrated that WYZ-L has the potential to use waste molasses and corn steep liquor as a resource for L(+)-lactic acid fermentation.

Production of L- and D-lactic acid from waste Curcuma longa biomass through simultaneous saccharification and cofermentation

Simultaneous saccharification and cofermentation (SSCF) of Curcuma longa waste biomass obtained after turmeric extraction to L- and D-lactic acid by Lactobacillus coryniformis and Lactobacillus paracasei, respectively, was investigated. This is a rich, starchy, agro-industrial waste with potential for use in industrial applications. After optimizing the fermentation of the biomass by adjusting nitrogen sources, enzyme compositions, nitrogen concentrations, and raw material concentrations, the SSCF process was conducted in a 7-l jar fermentor at 140 g dried material/L. The maximum lactic acid concentration, average productivity, reducing sugar conversion and lactic acid yield were 97.13 g/L, 2.7 g/L/h, 95.99% and 69.38 g/100 g dried material for L-lactic acid production, respectively and 91.61 g/L, 2.08 g/L/h, 90.53% and 65.43 g/100 g dried material for D-lactic acid production, respectively. The simple and efficient process described in this study could be utilized by C. longa residue-based lactic acid industries without requiring the alteration of plant equipment.

Understanding biorefining efficiency--the case of agrifood waste

The aim of this study was to determine biorefining efficiency according to the choices made in the entire value chain. The importance of the share of biomass volume biorefined or products substituted was investigated. Agrifood-waste-based biorefining represented the case. Anticipatory scenarios were designed for contrasting targets and compared with the current situation in two Finnish regions. Biorefining increases nutrient and energy efficiency in comparison with current use of waste. System boundaries decisively influence the relative efficiency of biorefining designs. For nutrient efficiency, full exploitation of biomass potential and anaerobic digestion increase nutrient efficiency, but the main determinant is efficient substitution for mineral fertilisers. For energy efficiency, combustion and location of biorefining close to heat demand are crucial. Regional differences in agricultural structure, the extent of the food industry and population density have a major impact on biorefining. High degrees of exploitation of feedstock potential and substitution efficiency are the keys.

Butanol production in a first-generation Brazilian sugarcane biorefinery: technical aspects and economics of greenfield projects

The techno-economics of greenfield projects of a first-generation sugarcane biorefinery aimed to produce ethanol, sugar, power, and n-butanol was conducted taking into account different butanol fermentation technologies (regular microorganism and mutant strain with improved butanol yield) and market scenarios (chemicals and automotive fuel). The complete sugarcane biorefinery with the batch acetone-butanol-ethanol (ABE) fermentation process was simulated using Aspen Plus®. The biorefinery was designed to process 2 million tonne sugarcane per year and utilize 25%, 50%, and 25% of the available sugarcane juice to produce sugar, ethanol, and butanol, respectively. The investment on a biorefinery with butanol production showed to be more attractive [14.8% IRR, P(IRR>12%)=0.99] than the conventional 50:50 (ethanol:sugar) annexed plant [13.3% IRR, P(IRR>12%)=0.80] only in the case butanol is produced by an improved microorganism and traded as a chemical.

Efficient production of L-lactic acid with high optical purity by alkaliphilic Bacillus sp. WL-S20

Highly efficient polymer-grade L-lactic acid production was achieved by an alkaliphilic strain Bacillus sp. WL-S20 using inexpensive peanut meal as nitrogen source and sodium hydroxide as neutralizing agent. In multi-pulse fed-batch fermentation of Bacillus sp. WL-S20, a L-lactic acid concentration of 225 g/l with a yield of 99.3% was obtained. In single-pulse fed-batch fermentation, a concentration of 180 g/l was obtained with a yield of 98.6%. No D-isomers of lactic acid were detected. The production of a high concentration of optically pure L-lactic acid by alkaliphilic Bacillus sp. WL-S20, combined with a low-cost nutrient and environment-friendly NaOH-based process, represent a potentially novel way for L-lactic acid production at an industrial scale.

Efficient production of D-(-)-lactic acid from broken rice by Lactobacillus delbrueckii using Ca(OH)2 as a neutralizing agent

Effects of Ca(OH)(2), NH(4)OH, and NaOH as neutralizing agents for efficient recovery of lactic acid was investigated. Lactic acid was produced from broken rice in a simultaneous saccharification and fermentation (SSF) process with Lactobacillus delbrueckii. Consumption of glucose (from broken rice) by the cells and the cell growth were the best with Ca(OH)(2) among the three neutralizing agents used. Maximum productivities of lactic acid reached with Ca(OH)(2), NH(4)OH, and NaOH were 3.59 g l(-1) h(-1), 1.51 g 1(-1) h(-1), and 1.40 g l(-1) h(-1), respectively. Ca(OH)(2) reduced the lactate molarity of the fermentation broth, and thus resulted in the highest lactic acid productivity. Furthermore, it was apparently clear that divalent cation (Ca(2+)) was more effective in neutralizing the cultures compared to monovalent (Na(+) and NH(3)(+)) cations.