Sequential solid-state and submerged cultivation of Aspergillus niger on sugarcane bagasse for the production of cellulase

Optimization and Bioreactor Scale-Up of Cellulase Production in Trichoderma sp. KMF006 for Higher Yield and Performance

This study optimized operating parameters to enhance cellulase production and evaluated scale-up feasibility in submerged fermentation (SmF) using Trichoderma sp. KMF006. Flask-scale experiments assessed the effects of Avicel:cellulose ratios (4:0-0:4), agitation speeds (150-210 rpm), and turbulence (baffled vs. non-baffled flasks), with optimized conditions applied to a 10 L bioreactor. A 3:1 Avicel:cellulose ratio (A3C1) significantly accelerated cellulase production, reaching peak activity 6 days earlier than Avicel alone. An agitation speed of 180 rpm was optimal, balancing enzyme activity and energy efficiency. Turbulence enhanced cellulase yields, with baffled flasks increasing EG, BGL, and CBH activities 19.9-, 6.2-, and 8.9-fold, respectively, compared to the control. Biochar further improved cellulase production but only under turbulent conditions, demonstrating a synergistic effect. At the bioreactor scale, the A3-180_Imp (A3C1, 180 rpm, impeller-induced turbulence) achieved the highest enzymatic activity (33.60 U/mL EG, 3.46 U/mL BGL, and 0.63 U/mL CBH). The filter paper unit (FPU) was 84 FPU/mL, a two-fold increase compared to the control. However, excessive turbulence at 210 rpm reduced enzyme stability, emphasizing the importance of balancing shear stress. These findings provide a systematic framework for optimizing SmF conditions, highlighting the significance of balancing hydrodynamic conditions for efficient cellulase production at an industrial scale.

Review of research progress on the production of cellulase from filamentous fungi

Cellulases have been widely used in many fields such as animal feed, textile, food, lignocellulose bioconversion, etc. Efficient and low-cost production of cellulases is very important for its industrial application, especially in bioconversion of lignocellulosic biomass. Filamentous fungi are currently widely used in industrial cellulase production due to their ability to secrete large amounts of active free cellulases extracellularly. This review comprehensively summarized the research progress on cellulases from filamentous fungi in recent years, including filamentous fungi used for cellulase production and its modification strategies, enzyme compositions, characterization methods and application of fungal cellulase systems, and the production of fungal cellulase includes production processes, factors affecting cellulase production such as inducers, fermentation medium, process parameters and their control strategies. Also, the future perspectives and research topics in fungal cellulase production are presented in the end of the review. The review helps to deepen the understanding of the current status of fungal cellulases, thereby promoting the production technology progress and industrial application of filamentous fungal cellulase.

Sequential cultivation method for β-fructofuranosidase production from Aspergillus tamarii URM4634, evaluation of their biochemical and kinetic/thermodynamic characteristics, and application on sucrose hydrolysis

The present study focused on evaluating the sequential fermentation (SF) method for FFase production from Aspergillus tamarii URM4634 using soybean bran as substrate. The SF was performed using soybean bran as substrate at 72 h and 30 °C and the maximum hydrolytic activity (44.00 U mL-1), corresponding to an increase of 2.98-fold to about SmF using sucrose as substrate. Already the maximum transfructosylating activity was 26.10 U mL-1. The FFase presents maximum hydrolytic activity at pH 5.0-6.0 and transfructosylating at pH 6.0 and 60 °C for both enzyme activities. The enzyme showed a typical hydrolytic kinetic profile evidenced by more affinity by sucrose hydrolysis reaction than the fructosyl transfer one. From kinetic and thermodynamic data of thermal denaturation, it was observed that the enzyme presents suitable at 55 °C, evidenced by the large half-life (990.21 min) and D values (3289.41 min). The maximum release of reducing sugars (8.45 g L-1) was obtained in hydrolysis of 20% sucrose during 180 min. The results obtained for FFase production by SF proved that this method can be used satisfactorily for sucrose-degrading enzymes and can contribute to the development of the SF technique to produce different industrial-interest enzymes.

Lignocellulolytic Enzymes Production by Four Wild Filamentous Fungi for Olive Stones Valorization: Comparing Three Fermentation Regimens

Lignocellulolytic enzymes play a crucial role in efficiently converting lignocellulose into valuable platform molecules in various industries. However, they are limited by their production yields, costs, and stability. Consequently, their production by producers adapted to local environments and the choice of low-cost raw materials can address these limitations. Due to the large amounts of olive stones (OS) generated in Morocco which are still undervalued, Penicillium crustosum, Fusarium nygamai, Trichoderma capillare, and Aspergillus calidoustus, are cultivated under different fermentation techniques using this by-product as a local lignocellulosic substrate. Based on a multilevel factorial design, their potential to produce lignocellulolytic enzymes during 15 days of dark incubation was evaluated. The results revealed that P. crustosum expressed a maximum total cellulase activity of 10.9 IU/ml under sequential fermentation (SF) and 3.6 IU/ml of β-glucosidase activity under submerged fermentation (SmF). F. nygamai recorded the best laccase activity of 9 IU/ml under solid-state fermentation (SSF). Unlike T. capillare, SF was the inducive culture for the former activity with 7.6 IU/ml. A. calidoustus produced, respectively, 1,009 μg/ml of proteins and 11.5 IU/ml of endoglucanase activity as the best results achieved. Optimum cellulase production took place after the 5th day under SF, while ligninases occurred between the 9th and the 11th days under SSF. This study reports for the first time the lignocellulolytic activities of F. nygamai and A. calidoustus. Furthermore, it underlines the potential of the four fungi as biomass decomposers for environmentally-friendly applications, emphasizing the efficiency of OS as an inducing substrate for enzyme production.

Successive process for efficient biovalorization of Brewers' spent grain to lignocellulolytic enzymes and lactic acid production through simultaneous saccharification and fermentation

This study aimed to increase the value of brewers' spent grain (BSG) by using it as feedstock to produce lignocellulolytic enzymes and lactic acid (LA). Twenty-two fungal strains were screened for lignocellulolytic enzyme production from BSG. Among them, Trichoderma sp. showed the highest cellulase activity (35.84 ± 0.27 U/g-BSG) and considerably high activities of xylanase (599.61 ± 23.09 U/g-BSG) and β-glucosidase (16.97 ± 0.77 U/g-BSG) under successive solid-state and submerged fermentation. The processes were successfully scaled up in a bioreactor. The enzyme cocktail was recovered and characterized. The maximum cellulase and xylanase activities were found at pH 5.0 and 50 °C, and the activities were highly stable at pH 4-8 and 30-50 °C. The enzyme cocktail was applied in simultaneous saccharification and fermentation of acid-pretreated BSG for LA production. The maximum LA obtained was 59.3 ± 1.0 g/L. This study has shown the efficient biovalorization of BSG, and this approach may also be applicable to other agro-industrial wastes.

An overview on the current status and future prospects in Aspergillus cellulase production

Cellulase is a new research point besides glucoamylase, amylase, and protease in the enzyme industry. Cellulase can decompose lignocellulosic biomass into small-molecule sugars, which facilitates microbial utilization; thus, it has a vast market potential in the field of feed, food, energy, and chemistry. The Aspergillus was the first strain used in cellulase preparation because of its safety and non-toxicity, strong growth ability, and high enzyme yield. This review provides the latest research and advances on preparing cellulase from Aspergillus. The metabolic mechanisms of cellulase secretion by Aspergillus, the selection of fermentation substrates, the comparison of the fermentation modes, and the effect of fermentation conditions have been discussed in this review. Also, the subsequent separation and purification techniques of Aspergillus cellulase, including salting out, organic solvent precipitation, ultrafiltration, and chromatography, have been declared. Further, bottlenecks in Aspergillus cellulase preparation and corresponding feasible approaches, such as genetic engineering, mixed culture, and cellulase immobilization, have also been proposed in this review. This paper provides theoretical support for the efficient production and application of Aspergillus cellulase.

Enhanced biovalorization of palm biomass wastes as biodiesel feedstocks through integrated solid-state and submerged fermentations by fungal co-cultures

Palm empty fruit bunches (EFB) were valorized into fungal lipids by oleaginous fungus Aspergillus tubingensis TSIP9 under solid-state fermentation (SSF) and submerged fermentation (SmF). An integrated SSF-SmF process increased lipid production from 116.2 ± 0.1 mg/g-EFB under SSF and 60.1 ± 0.2 under SmF up to 124.9 ± 0.5 mg/g-EFB, possibly due to the combined benefits of dispersed mycelia forming during SSF and better mass transfer during SmF. As A. tubingensis lacks sufficient β-glucosidase, it was co-cultured with high β-glucosidase-producing Trichoderma reesei QM 9414. The co-cultures improved overall lipid yields likely due to synergistic interaction of the two fungi. After inoculum size was optimized and the co-cultures were performed in bioreactors, the lipid yield was increased up to 205.1 ± 1.1 mg/g-EFB. The fatty acid composition of fungal lipids indicated their potential use as biodiesel feedstocks. The fungal fermentation of EFB also provided cellulose pulp residues. These strategies could be practical options for low-cost biovalorization of biomass wastes.

Combination of Solid State and Submerged Fermentation Strategies to Produce a New Jellyfish-Based Food

This study describes the set-up and optimization of a fermentation strategy applied to a composite raw material containing jellyfish biomass as the principal ingredient. New fermented food was developed by combining fresh jellyfish Rhizostoma pulmo and the sequential solid-state submerged liquid fermentation method used in Asian countries for processing a high-salt-containing raw material. Aspergillus oryzae was used to drive the first fermentation, conducted in solid-state conditions, of a jellyfish-based product, here named Jelly paste. The second fermentation was performed by inoculating the Jelly paste with different selected bacteria and yeasts, leading to a final product named fermented Jellyfish paste. For the first time, a set of safety parameters necessary for monitoring and describing a jellyfish-based fermented food was established. The new fermented products obtained by the use of Debaryomyces hansenii BC T3-23 yeast strain and the Bacillus amyloliquefaciens MS3 bacterial strain revealed desirable nutritional traits in terms of protein, lipids and total phenolic content, as well as valuable total antioxidant activity. The obtained final products also showed a complex enzyme profile rich in amylase, protease and lipase activities, thus making them characterized by unique composite sensory odor descriptors (umami, smoked, dried fruit, spices).

Strategies to enhance enzymatic hydrolysis of lignocellulosic biomass for biorefinery applications: A review

Global interest in lignocellulosic biorefineries has increased in the recent past due to technological advancements in sustainable and cost-effective production of numerous commodity and speciality chemicals and fuels from renewable lignocellulosic biomass (LCB). As a result, the market value of biorefinery products has also increased over the time, with an estimated worth of USD 867.7 billion by 2025. However, biorefinery operations, especially enzymatic hydrolysis, suffer from many challenges that limits the cost-effectiveness of conversion of LCB. Therefore, it is essential to understand and address these challenges in future biorefineries. The paper focuses on recent trends and challenges in enzymatic hydrolysis of LCB during lignocellulosic biorefinery operation for greener synthesis of energy, fuels, chemicals and other high-value products. Insights into the gaps in knowledge and technological challenges have also been addressed together with focus on future research needs and perspectives of enzymatic hydrolysis of LCB for biorefinery applications.

Kinetic Model for Enzymatic Hydrolysis of Cellulose from Pre-Treated Rice Husks

Rice husks contain cellulose as a raw material for manufacturing second-generation bioethanol. Cellulose from pre-treated rice husks was converted into reducing sugars through enzymatic hydrolysis using enzymes derived from Aspergillus niger. This study aims to determine the kinetics of enzymatic hydrolysis at enzyme concentrations of 10, 15, and 20% (v/w) and hydrolysis times of 5, 10, 15, 20, and 25 h. The results showed that cellulose was hydrolyzed to form reducing sugars. The CMCase activity and FPase activity reached 548.940 and 314.892 U mL−1, respectively, much higher than most previous reports on this genus. From the calculation of the reaction rate using the Michaelis–Menten kinetic model, the value of the Michaelis constant ranges from 0.001 to 0.0007, and the maximum rate is 1.3 × 10−7 to 2.7 × 10−7 Mol L−1 s−1. The highest reducing sugar concentration was obtained (1.80 g L−1) at an enzyme concentration of 20% (v/w) and a hydrolysis time of 25 h.

Optimisation of Xylanase–Pectinase Cocktail Production with Bacillus amyloliquefaciens ADI2 Using a Low-Cost Substrate via Statistical Strategy

An effective statistical tool for increasing and boosting the production of xylanase and pectinase by Bacillus amyloliquefaciens ADI2 during submerged fermentation (SmF) appears to be the response of surface methodology (RSM) using the central composite design (CCD). Optimum production was achieved under fermentation conditions of a temperature of 28 °C, pH of 8.38, inoculum size of 4% (w/v) and agitation speed of 94 rpm for 48 h. The experimental responses demonstrated a near agreement with the expected responses under optimum conditions of independent variables, suggesting the model’s validity. The optimised CCD model had a 1.34-fold, 159 ± 6 U/mL greater xylanase and 5.96-fold, 205 ± 9 U/mL greater pectinase production than the one factor at a time (OFAT) approach. The production of concurrent enzymes of xylanase–pectinase resulted in a ratio of 1:1.3.

Cellulase production by Aspergillus niger using urban lignocellulosic waste as substrate: Evaluation of different cultivation strategies

Cellulases are used in various industries, acting efficiently and sustainably in the degradation of cellulose contained in different raw materials and recovering high value products. It is the third largest group of enzymes consumed industrially, as they are required in processes linked to the food, biofuel, textile, cleaning products, among others. However, the main disadvantage in the use of commercial cellulases is the high cost. In this context, the objective of this work was to determine conditions for obtaining more efficient and economical cellulases. For this, the efficiency in obtaining the extracellular cellulases endoglucanase (CMCase) and exoglucanase (FPase) by a fungus Aspergillus niger was investigated using an urban lignocellulosic waste as substrate characterized by tree leaves collected from squares and avenues in urban areas. As urban lignocellulosic waste is an innovative raw material, its chemical composition was determined. This substrate contains 20.36% cellulose and induced the production of cellulases in all fermentation methods, proving to be a promising and sustainable source. The influence of the nutrient medium on CMCase and FPase activities was evaluated for three different sequential fermentation (SF) configurations. Medium 2 provided an increase of up to 100 U/L of CMCase and FPase in relation to medium 1. The interactive effect of pH and moisture content on CMCase e FPase production under SF was studied in a central composite design (CCD). Also, different fermentation methods (solid state, submerged and sequential) were evaluated. The use of SF increased the enzymatic activities of both cellulases by 140% compared to other conventional methods and also stood out in the production of proteins (270.05 μg/mL) and reducing sugars (1.19 mg/mL). The desirability function determined the optimal activities of CMCase and FPase as 413.49 U/L and 230.68 U/L, respectively, obtained from the optimal variables of pH 5.5 and 75% moisture content under SF. The effect of pH and moisture content on the activity of each cellulase was analyzed using the Pareto chart and response surface methodology (RSM). These results revealed favorable strategies for cellulase production, such as the use of urban lignocellulosic waste, SF and ideal operational conditions.

Production of Endoglucanases by Streptomyces thermocoprophilus CP1 using Rice Straw as a Substrate

Rice straw is a major agricultural waste that can be used as an alternative substrate to expensive raw materials for endoglucanases (CMCase) production by microorganisms. This study aimed to search for a microorganism having the potential to produce endoglucanase from rice straw. From compost samples, 40 bacterial colonies were isolated on carboxymethylcellulose (CMC) agar. Among them, 16 isolates showed a hydrolysis zone on a CMC agar plate with hydrolysis (HC) values ranging from 1.15±0.02 to 4.40±0.52. Based on hydrolysis zone diameter and HC value, isolates CP1, CP2 and CP3 were further examined for their CMCase production in CMC broth. According to CMCase production and stability, isolate CP1 was selected for further study. The optimal pH and temperature for CMCase production of isolate CP1 were 5 and 45 °C, respectively. When using pre-treated rice straw as a substrate for semi-solid-state fermentation, the highest CMCase activity of 0.142 ± 0.008 U/mL was obtained in a medium containing pre-treated rice straw of 60 g/L. The sequence alignment analysis and phylogenetic analysis suggested that the isolate CP1 was likely to be Streptomyces thermocoprophilus. The microorganism obtained from this study may be not only industrially important but also beneficial to the environment.

Screening of Lignocellulolytic Enzyme Activities in Fungal Species and Sequential Solid-State and Submerged Cultivation for the Production of Enzyme Cocktails

Various fungal species can degrade lignocellulolytic materials with their enzyme cocktails composed of cellulolytic and lignolytic enzymes. In this work, seven fungal species (Mucor indicus DSM 2185, Paecilomyces variotii CBS 372.70, Myceliophthora thermophila CBS 663.74, Thielavia terrestris CBS 456.75, Botryosphaeria dothidea JCM 2738, Fusarium oxysporum f.sp. langenariae JCM 9293, and Fusarium verticillioides JCM 23107) and four nutrient media were used in the screening for effective lignocellulose degrading enzymes. From the seven tested fungi, F. oxysporum and F. verticilliodes, along with nutrient medium 4, were selected as the best medium and producers of lignocellulolytic enzymes based on the determined xylanase (>4 U mg-1) and glucanase activity (≈2 U mg-1). Nutrient medium 4 supplemented with pretreated corn cobs was used in the production of lignocellulolytic enzymes by sequential solid-state and submerged cultivation of F. oxysporum, F. verticilliodes, and a mixed culture of both strains. F. oxysporum showed 6 times higher exoglucanase activity (3.33 U mg-1) after 5 days of cultivation in comparison with F. verticillioides (0.55 U mg-1). F. oxysporum also showed 2 times more endoglucanase activity (0.33 U mg-1). The mixed culture cultivation showed similar endo- and exoglucanase activities compared to F. oxysporum (0.35 U mg-1; 7.84 U mg-1). Maximum xylanase activity was achieved after 7 days of cultivation of F. verticilliodes (≈16 U mg-1), while F. oxysporum showed maximum activity after 9 days that was around 2 times lower compared to that of F. verticilliodes. The mixed culture achieved maximum xylanase activity after only 4 days, but the specific activity was similar to activities observed for F. oxysporum. It can be concluded that both fungal strains can be used as producers of enzyme cocktails for the degradation of lignocellulose containing raw materials, and that corn cobs can be used as an inducer for enzyme production.

Bioenergy from dairy manure: technologies, challenges and opportunities

Dairy manure (DM) is a kind of cheap cellulosic biomass resource which includes lignocellulose and mineral nutrients. Random stacks not only leads damage to the environment, but also results in waste of natural resources. The traditional ways to use DM include returning it to the soil or acting as a fertilizer, which could reduce environmental pollution to some extent. However, the resource utilization rate is not high and socio-economic performance is not utilized. To expand the application of DM, more and more attention has been paid to explore its potential as bioenergy or bio-chemicals production. This article presented a comprehensive review of different types of bioenergy production from DM and provided a general overview for bioenergy production. Importantly, this paper discussed potentials of DM as candidate feedstocks not only for biogas, bioethanol, biohydrogen, microbial fuel cell, lactic acid, and fumaric acid production by microbial technology, but also for bio-oil and biochar production through apyrolysis process. Additionally, the use of manure for replacing freshwater or nutrients for algae cultivation and cellulase production were also discussed. Overall, DM could be a novel suitable material for future biorefinery. Importantly, considerable efforts and further extensive research on overcoming technical bottlenecks like pretreatment, the effective release of fermentable sugars, the absence of robust organisms for fermentation, energy balance, and life cycle assessment should be needed to develop a comprehensive biorefinery model.

Current perspective on production and applications of microbial cellulases: a review

The potential of cellulolytic enzymes has been widely studied and explored for bioconversion processes and plays a key role in various industrial applications. Cellulase, a key enzyme for cellulose-rich waste feedstock-based biorefinery, has increasing demand in various industries, e.g., paper and pulp, juice clarification, etc. Also, there has been constant progress in developing new strategies to enhance its production, such as the application of waste feedstock as the substrate for the production of individual or enzyme cocktails, process parameters control, and genetic manipulations for enzyme production with enhanced yield, efficiency, and specificity. Further, an insight into immobilization techniques has also been presented for improved reusability of cellulase, a critical factor that controls the cost of the enzyme at an industrial scale. In addition, the review also gives an insight into the status of the significant application of cellulase in the industrial sector, with its techno-economic analysis for future applications. The present review gives a complete overview of current perspectives on the production of microbial cellulases as a promising tool to develop a sustainable and greener concept for industrial applications.

Sugarcane bagasse: a biomass sufficiently applied for improving global energy, environment and economic sustainability

Sugarcane (Saccharum officinarum) bagasse (SCB) is a biomass of agricultural waste obtained from sugarcane processing that has been found in abundance globally. Due to its abundance in nature, researchers have been harnessing this biomass for numerous applications such as in energy and environmental sustainability. However, before it could be optimally utilised, it has to be pre-treated using available methods. Different pre-treatment methods were reviewed for SCB, both alkaline and alkali-acid process reveal efficient and successful approaches for obtaining higher glucose production from hydrolysis. Procedures for hydrolysis were evaluated, and results indicate that pre-treated SCB was susceptible to acid and enzymatic hydrolysis as > 80% glucose yield was obtained in both cases. The SCB could achieve a bio-ethanol (a biofuel) yield of > 0.2 g/g at optimal conditions and xylitol (a bio-product) yield at > 0.4 g/g in most cases. Thermochemical processing of SCB also gave excellent biofuel yields. The plethora of products obtained in this regard have been catalogued and elucidated extensively. As found in this study, the SCB could be used in diverse applications such as adsorbent, ion exchange resin, briquettes, ceramics, concrete, cement and polymer composites. Consequently, the SCB is a biomass with great potential to meet global energy demand and encourage environmental sustainability.

Use of a Sequential Fermentation Method for the Production of Aspergillus tamarii URM4634 Protease and a Kinetic/Thermodynamic Study of the Enzyme

Microbial proteases are commonly produced by submerged (SmF) or solid-state fermentation (SSF), whose combination results in an unconventional method, called sequential fermentation (SF), which has already been used only to produce cellulolytic enzymes. In this context, the aim of the present study was the development of a novel SF method for protease production using wheat bran as a substrate. Moreover, the kinetic and thermodynamic parameters of azocasein hydrolysis were estimated, thus providing a greater understanding of the catalytic reaction. In SF, an approximately 9-fold increase in protease activity was observed compared to the conventional SmF method. Optimization of glucose concentration and medium volume by statistical means allowed us to achieve a maximum protease activity of 180.17 U mL−1. The obtained enzyme had an optimum pH and temperature of 7.0 and 50 °C, respectively. Kinetic and thermodynamic parameters highlighted that such a neutral protease is satisfactorily thermostable at 50 °C, a temperature commonly used in many applications in the food industry. The results obtained suggested not only that SF could be a promising alternative to produce proteases, but also that it could be adapted to produce several other enzymes.

Purification and characterization of a highly-stable fungal xylanase from Aspergillus tubingensis cultivated on palm wastes through combined solid-state and submerged fermentation

Fungal xylanase was produced from lignocellulosic palm wastes through combined solid-state fermentation (SSF) and submerged fermentation (SmF) by Aspergillus tubingensis TSIP9 in a helical-impeller equipped bioreactor. The combined SSF-SmF promoted the xylanase production by 15 and 70% higher than SSF and SmF, respectively. Sequential purification yielded 7.4-fold purified xylanase with 9.07% recovery. The maximum activities of crude and purified xylanase were observed at the same pH of 5.0 and the same temperature of 50 °C while purified xylanase is more active and highly stable at a wider pH range of 3-8 and temperature of 30-60 °C. The half-life of purified xylanase at various temperatures was also much improved by 2-8 folds compared to crude xylanase. Michaelis-Menten constants, V_max and K_m, for purified xylanase are 2,602.8 U/mg and 32.4 mg/mL, respectively. Purified xylanase activity was most enhanced with Ca²⁺ followed by Zn²⁺ and Fe²⁺ at 10 mM while significantly inhibited by Co²⁺, Cu²⁺, Pb²⁺, and Ag⁺. This study has shown the effectiveness of combined SSF-SmF for xylanase production and superior properties of purified xylanase for industrial processes.

Cost-effective production of biocatalysts using inexpensive plant biomass: a review

Enzymes are the complex protein moieties, catalyze the rate of chemical reactions by transforming various substrates to specific products and play an integral part in multiple biochemical cycles. Advancement in enzyme research and its integration with industries have reformed the biotech industries. It provides a superior monetary and ecological exchange to traditional material measures in an efficient and environmentally sustainable manner. The cost-effective production of pure and highly active enzymes is still a challenge for the biocatalyst industries. The use of high purity substrates further raises the cost of a typical biocatalyst. The use of low-cost plant-based biomasses as an enticing and sustainable substrate for enzyme production is the most cost-effective approach to these problems. Given the relevance of biomass as a substrate for enzyme development, this review article focuses on the key source, composition and major enzyme generated using various biomass residues. Furthermore, the difficulties associated with the use of biomass as a substrate and technical developments in this area, are also addressed. The use of waste biomass as a substrate lowers the ultimate cost for the production of biocatalysts while simultaneously reduces the waste burden from the environment.

Potential Role of Sequential Solid-State and Submerged-Liquid Fermentations in a Circular Bioeconomy

An efficient processing of organic solid residues will be pivotal in the development of the circular bioeconomy. Due to their composition, such residues comprise a great biochemical conversion potential through fermentations. Generally, the carbohydrates and proteins present in the organic wastes cannot be directly metabolized by microorganisms. Thus, before fermentation, enzymes are used in a hydrolysis step to release digestible sugars and nitrogen. Although enzymes can be efficiently produced from organic solid residues in solid-state fermentations (SsF), challenges in the development and scale-up of SsF technologies, especially bioreactors, have hindered a wider application of such systems. Therefore, most of the commercial enzymes are produced in submerged-liquid fermentations (SmF) from expensive simple sugars. Instead of independently evaluating SsF and SmF, the review covers the option of combining them in a sequential process in which, enzymes are firstly produced in SsF and then used for hydrolysis, yielding a suitable medium for SmF. The article reviews experimental work that has demonstrated the feasibility of the process and underlines the benefits that such combination has. Finally, a discussion is included which highlights that, unlike typically perceived, SsF should not be considered a counterpart of SmF but, in contrast, the main advantages of each type of fermentation are accentuated in a synergistic sequential SsF-SmF.

The Potential of Single-Cell Oils Derived From Filamentous Fungi as Alternative Feedstock Sources for Biodiesel Production

Microbial lipids, also known as single-cell oils (SCOs), are highly attractive feedstocks for biodiesel production due to their fast production rates, minimal labor requirements, independence from seasonal and climatic changes, and ease of scale-up for industrial processing. Among the SCO producers, the less explored filamentous fungi (molds) exhibit desirable features such as a repertoire of hydrolyzing enzymes and a unique pellet morphology that facilitates downstream harvesting. Although several oleaginous filamentous fungi have been identified and explored for SCO production, high production costs and technical difficulties still make the process less attractive compared to conventional lipid sources for biodiesel production. This review aims to highlight the ability of filamentous fungi to hydrolyze various organic wastes for SCO production and explore current strategies to enhance the efficiency and cost-effectiveness of the SCO production and recovery process. The review also highlights the mechanisms and components governing lipogenic pathways, which can inform the rational designs of processing conditions and metabolic engineering efforts for increasing the quality and accumulation of lipids in filamentous fungi. Furthermore, we describe other process integration strategies such as the co-production with hydrogen using advanced fermentation processes as a step toward a biorefinery process. These innovative approaches allow for integrating upstream and downstream processing units, thus resulting in an efficient and cost-effective method of simultaneous SCO production and utilization for biodiesel production.

Lignocellulose hydrolytic enzymes production by Aspergillus flavus KUB2 using submerged fermentation of sugarcane bagasse waste

Lignocellulosic wastes, rice straw, sugarcane bagasse, rice bran and sawdust, and pure commercial carboxymethyl cellulose (CMC) and xylan were used as substrates to cultivate cellulolytic fungus, Aspergillus flavus KUB2, in submerged fermentation at 30°C. Of all the substrates, sugarcane bagasse was a good source for the production of cellulolytic and also hemicellulolytic enzymes. The maximum activities of endoglucanase (CMCase), total cellulase (FPase) and xylanase using sugarcane bagasse as substrate were 8%, 75% and 165%, respectively, higher than those of the commercial substrates. The time course determination of enzyme production revealed that the highest CMCase (1.27 U/ml), FPase (0.72 U/ml) and xylanase (376.81 U/ml) activities were observed at 14 days of fermentation. Fourier transform infrared (FTIR) spectroscopy and scanning electron microscopy (SEM) analyses confirmed the efficient structural alteration of sugarcane bagasse caused by enzymatic actions during A. flavus KUB2 cultivation. Based on the results of the hydrolytic enzyme activities, FTIR and SEM, A. flavus KUB2 is suggested as an efficient hydrolytic enzymes producer and an effective lignocellulose degrader, while sugarcane bagasse can be applied as a low-cost carbon source for the economical production of lignocellulose hydrolytic enzymes by A. flavus KUB2.

Solid-state fermentation increases secretome complexity in Aspergillus brasiliensis

Aspergillus is used for the industrial production of enzymes and organic acids, mainly by submerged fermentation (SmF). However, solid-state fermentation (SSF) offers several advantages over SmF. Although differences related to lower catabolite repression and substrate inhibition, as well as higher extracellular enzyme production in SSF compared to SmF have been shown, the mechanisms undelaying such differences are still unknown. To explain some differences among SSF and SmF, the secretome of Aspergillus brasiliensis obtained from cultures in a homogeneous physiological state with high glucose concentrations was analyzed. Of the regulated proteins produced by SmF, 74% were downregulated by increasing the glucose concentration, whereas all those produced by SSF were upregulated. The most abundant and upregulated protein found in SSF was the transaldolase, which could perform a moonlighting function in fungal adhesion to the solid support. This study evidenced that SSF: (i) improves the kinetic parameters in relation to SmF, (ii) prevents the catabolite repression, (iii) increases the branching level of hyphae and oxidative metabolism, as well as the concentration and diversity of secreted proteins, and (iv) favors the secretion of typically intracellular proteins that could be involved in fungal adhesion. All these differences can be related to the fact that molds are more specialized to growth in solid materials because they mimic their natural habitat.

Newly designed multi-stacked circular tray solid-state bioreactor: analysis of a distributed parameter gas balance during solid-state fermentation with influence of variable initial moisture content arrangements

Background

The growth of Aspergillus awamori and Aspergillus oryzae in a self-designed, multi-stacked circular tray solid-state bioreactor (SSB), operating in solid-state fermentation (SSF) conditions at a laboratory scale, was studied. The bioreactor was divided into six layers by six circular perforated trays. Wheat bran was used as both a carrier of bound mycelia and nutrient medium for the growth of A. awamori and A. oryzae. The new tray SSB is equipped with instrumentation (an oxygen (O2)/carbon dioxide (CO2) gas analyser and a thermocouple) to continuously monitor O2 consumption and CO2 and heat evolved, which can directly be used to monitor the fungal biomass. The integrated Gompertz model was used to describe the accumulated evolution of CO2.

Results

The results from the models strongly suggest that the evolved and accumulated CO2 can be used to excellently describe fungal growth. Another important parameter that can be determined by the gas balance method is the respiratory quotient (RQ). This is the ratio of the CO2 evolution rate (CER) to the O2 uptake rate (OUR). The use of CER and OUR confirmed that correlated measurements of microbial activity are available, and the determination of RQ may propose an explanation for differences from expected levels. The kinetic behaviour of the fungal culture, using raw CO2, which represents an accumulation term, was integrated with respect to time and fitted to a Gompertz model, a log-like equation. The model can be used to generate parameter values that may be used to verify the experimental data, and also to simulate and optimise the process.

Conclusion

Overall, A. awamori and A. oryzae have their own ability to degrade and utilise the complex compositions contained in the solid substrate, and fermentation conditions may lead to possible comparisons. In addition, multi-stacked circular tray SSB systems demonstrated an excellent system for further investigations of mass transfer and possibly for large-scale operation, though considerable optimisation work remains to be done; for example, the height/diameter ratio and total number of trays should be optimised.

Interaction Between Cobalt Ferrite Nanoparticles and Aspergillus niger Spores

The immobilization of microorganisms has been reported as an alternative to improve the efficiency of processes such as fermentation, anaerobic digestion, bioadsorption, and many others. Since the kinetics of bioprocesses are governed by the adsorbent/adsorbate interaction, it is important to know the mechanisms of interaction between biological materials and supports. This could help to define optimal operating conditions. In this research, the fungus that produces the cellulases, was selected, and the characterization of the interaction between fungal spores and cobalt ferrite magnetic nanoparticles, was performed. In order to select a fungal strain produces cellulase enzymes, a qualitative Congo Red test was carried out with a culture medium rich in carboxymethylcellulose. From five strains, Aspergillus niger was selected. Chitosan coated cobalt ferrite magnetic nanoparticles (CoMNP-C) were synthesized by single-step co-precipitation. The nano-size of CoMNP-C was demonstrated by XRD. The presence of a high content of amino groups (0.144 mM g^-1) was observed, that could have an important role in the interaction between nanoparticles and spores. Adsorption kinetic studies were carried out. The pseudo-equilibrium time was estimated as 90 min. Spores adsorption isotherm was obtained with 3.45 mg of synthesized material at 30 °C. It was found that the adsorption of spores may be described by both models (Langmuir and Freundlich), suggesting a homogeneous surface of the nanoparticles and a multilayer adsorption phenomenon. These results can have transcendence in multiple applications based on the studied process.

Combining submerged and solid state fermentation to convert waste bread into protein and pigment using the edible filamentous fungus N. intermedia

Waste streams from ethanol and bread production present inexpensive, abundant and underutilized renewable substrates that are highly available for valorisation into high-value products. A combined submerged to solid state fermentation strategy was studied using the edible filamentous fungus Neurospora intermedia to biotransform ethanol plant residues 'thin stillage' and waste bread as substrates for the production of additional ethanol, biomass and a feed product rich in pigment. The fungus was able to degrade the stillage during submerged fermentation, producing 81 kg ethanol and 65 kg fungal biomass per ton dry weight of thin stillage. Concurrently, the second solid state fermentation step increased the protein content in waste bread by 161%. Additionally, 1.2 kg pigment per ton waste bread was obtained at the best conditions (6 days solid state fermentation under light at 95% relative humidity at 35 °C with an initial substrate moisture content of 40% using washed fungal biomass to initiate fermentation). This study presents a means of increasing the value of waste bread while reducing the treatment load on thin stillage in ethanol plants.

High cellulolytic activities in filamentous fungi isolated from an extreme oligotrophic subterranean environment (Catão cave) in Brazil

Isolation and screening of new fungal strains from extreme and understudied environments, such as caves, is a promising approach to find higher yields enzyme producers. Cellulolytic fungal strains isolated from a Brazilian cave were evaluated for their enzymatic production after submerged (SmF) and solid-state fermentation (SSF). After SmF, three strains were selected for their high enzymatic activities: Aspergillus ustus for endoglucanase (4.76 U/mg), Talaromyces bruneus for β-glucosidase (11.71 U/mg) and Aspergillus sp. (CBMAI 1926) for total cellulase (1.70 U/mg). After SSF, these strains, showed better yields compared to the reference strain Aspergillus niger 3T5B8. Aspergillus sp. (CBMAI 1926) stood out as a new species that expressed activity of total cellulases (0.10 U/mg) and low protein concentration (0.44 mg/mL). In conclusion, these isolated strains have a more efficient and promising cellulolytic enzyme complex that can be used in fermentation and saccharification processes with a lower protein concentration and a higher enzymatic activity than the reference strain. Therefore, beside the new genetic material characterized, our study highlights the benefits of cave extreme environments exploitation to find new potentially valuable strains.

Fathoming Aspergillus oryzae metabolomes in formulated growth matrices

The stochasticity of Aspergillus oryzae (Trivially: the koji mold) pan-metabolomes commensurate with its ubiquitously distributed landscapes, i.e. growth matrices have been seemed uncharted since its food fermentative systems are mostly being investigated. In this review, we explicitly have discussed the likely tendencies of A. oryzae metabolomes pertaining to its growth milieu formulated with substrate matrices of varying nature, composition, texture, and associated physicochemical parameters. We envisaged typical food matrices, namely, meju, koji, and moromi as the semi-natural cultivation models toward delineating the metabolomic patterns of the koji mold, which synergistically influences the organoleptic and functional properties of the end products. Further, we highlighted how tailored conditions in sub-natural growth matrices, i.e. synthetic cultivation media blends, inducers, and growth surfaces, may influence A. oryzae metabolomes and targeted phenotypes. In general, the sequential or synchronous growth of A. oryzae on formulated matrices results in a number of metabolic tradeoffs with its immediate microenvironment influencing its adaptive and regulatory metabolomes. In broader context, evaluating the metabolic plasticity of A. oryzae relative to the tractable variables in formulated growth matrices might help approximate its growth and metabolism in the more complex natural matrices and environs. These approaches may considerably help in the design and manipulation of hybrid cultivation systems towards the efficient harnessing of commercial molds.

Production, purification, characterization and application of a new halotolerant and thermostable endoglucanase of Botrytis ricini URM 5627

A halotolerant endoglucanase with a molecular mass of 39 kDa was obtained from the solid fermentation of sugarcane bagasse by the fungus Botrytis ricini URM 5627 and isolated using only two purification processes: fractionation with ammonium sulphate and size-exclusion chromatography resulting in an activity of 1289.83 U/mL. After the isolation, biochemical characterizations were performed, giving a temperature of 50 °C and optimum pH of 5. The enzyme was stable at 39-60 °C for 60 min and at a pH of 4-6. The enzymatic activity increased in the presence of Na⁺, Mn²⁺, Mg²⁺ and Zn²⁺ and decreased in the presence of Ca²⁺, Cu²⁺, and Fe²⁺. The endoglucanase revealed a halotolerant profile since its activity increased proportionally to an increase in NaCl concentration. The maximum activity was reached at 2 M NaCl with a 75% increase in activity. The enzyme had a K_m of 0.1299 ± 0.0096 mg/mL and a V_max of 0.097 ± 0.00121 mol/min/mL. During application in saccharification tests, the enzyme was able to hydrolyse sugarcane bagasse, rice husk, and wheat bran, with the highest production of reducers/fermentable sugars within 24 h of saccharification for wheat bran (137.21 mg/g). Therefore, these properties combined make this isolated enzyme a potential candidate for biotechnological and industrial applications.

Improved production of cellulase by Trichoderma reesei (MTCC 164) from coconut mesocarp-based lignocellulosic wastes under response surface-optimized condition

Experimental investigations were carried out to develop economic production process of cellulase using coconut mesocarp as an inexpensive lignocellulosic inducer while replacing commercial cellulose. Cellulase production was initially investigated from commercial cellulose in different submerged conditions using Trichoderma reesei (MTCC 164). Maximum enzyme production was achieved 6.3 g/l with activity level 37 FPU/ml in the condition where cellulose to water content ratio was maintained at 5:35 (W/V). To achieve similar maximum production of cellulase from coconut mesocarp, response surface methodology was implemented to optimize most influencing parameters. Most influencing nutritional parameters such as coconut mesocarp, glucose and peptone were optimized in the concentration ranges of 35 g/l, 35 g/l and 25 g/l, respectively. Selecting optimized parameter values, fermentations were conducted inside the fermenter with 2 L operating volume to ensure high concentration and activity profiles of enzyme. Enzyme concentration was achieved 7.20 g/l after 96 h of batch fermentation with specific activity levels of 42 FPU/ ml and CMCase 75 U/ml. Enzyme concentration was further improved to 9.58 g/l with activity levels of 54 FPU/ml and CMCase 93 U/ml by adopting sequential feeding of coconut mesocarp in fed-batch fermentation mode. The presence of pure cellulase in the sample was confirmed by FTIR analysis.

Cellulase production by white-rot basidiomycetous fungi: solid-state versus submerged cultivation

White-rot basidiomycetous (WRB) fungi are a group of wood-decaying fungi that are known to be endowed with the ability to secrete enzymes that can catalyze decomposition of a range of plant cell wall polysaccharides, including cellulose and lignin. Expression of these enzymes is induced by the substrate and the enzyme yields obtained depend on the growth of the fungi and thus the mode of cultivation. In order to exploit WRB fungi for local enzyme production for converting lignocellulosic materials in biorefinery processes, the fungi can principally be cultivated in either solid-state (SSC) or submerged cultivation (SmC) systems. In this review, we quantitatively assess the data available in the literature on cellulase production yields by WRB fungi cultivated by SSC or SmC. The review also assesses cellulolytic enzyme production rates and enzyme recovery when WRB fungi are cultivated on different biomass residues in SSC or SmC systems. Although some variation in cellulase production yields have been reported for certain substrates, the analysis convincingly shows that SmC is generally more efficient than SSC for obtaining high cellulase production yields and high cellulase production rates on the substrate used. However, the cultivation method also affects the enzyme activity profile obtained, and the resulting enzyme titers and significant dilution of the enzymes usually occurs in SmC. The review also highlights some future approaches, including sequential cultivations and co-cultivation of WRB fungi for improved enzyme expression, as well as on-site approaches for production of enzyme blends for industrial biomass conversion. The quantitative comparisons made have implications for selection of the most appropriate cultivation method for WRB fungi for attaining maximal cellulase production.

Bioreactors in solid state fermentation technology: Design, applications and engineering aspects

In recent years, substantial credibility in employing Solid-State Fermentation (SSF) technique has been witnessed owing to its numerous advantages over submerged fermentation (SmF). In spite of enormous advantages, true potential of SSF technology has not been fully realized at industrial scale. The lack of rational and scalable bioreactor designs backed by mathematical models and automated control system that could successfully address heterogeneity with respect to heat and mass, and also operate aseptically, remains the prime reason for it. As a result, there still exists vast scope in SSF bioreactor research and development to facilitate broad spectrum of biotechnological applications. The present article reviews state-of-the-art in SSF technology with focus on bioreactors that have been employed for bioprocess applications, in particular, enzyme production. Based on the mode of operation, bioreactors are divided into four categories with emphasis on design features, effect of operating conditions on productivity, applications and limitations. Selected modeling studies developed over the years, have been revised and presented in problem specific manner in order to address the limitations. Some interesting designs including few recent ones that have been proposed and/or employed at pilot and industrial levels are discussed in more detail.

A closed-loop strategy for endoglucanase production using sugarcane bagasse liquefied by a home-made enzymatic cocktail

Use of the same lignocellulosic biomass as feedstock for enzymes and ethanol production has been suggested as a lower cost option in future biorefineries. Here, we propose a closed-loop strategy to produce the cellulolytic enzymes required for biomass hydrolysis using sugarcane bagasse liquefied by a home-made enzymatic cocktail as carbon source and inducer. The fed-batch liquefaction conditions were firstly evaluated using commercial enzymes. Subsequently, the effects of different liquefied materials and solids loadings on endoglucanase production by Aspergillus niger cultivated in submerged fermentation were investigated. The liquefied bagasse produced using the home-made cocktail was more favorable for endoglucanase production, resulting in improvement up to 17%, compared to bagasse liquefied by commercial enzymes. The results indicated that liquefied bagasse produced by home-made enzymatic cocktail could provide a cost-effective carbon source and inducer for cellulolytic enzyme production, and could contribute to closing loops within the biorefinery, thus reducing costs and minimizing waste.

Characterization of cellulase from Aspergillus tubingensis NKBP-55 for generation of fermentable sugars from agricultural residues

The aim of this work was to characterize cellulase from Aspergillus tubingensis NKBP-55 for generation of fermentable sugars from agricultural residues. The strain produced high titres of cellulase (750 U/gds) on copra meal in solid state fermentation (SSF). The enzyme preparation also showed hemicellulolytic activities (U/gds) viz. endo-mannanase (1023), endo-xylanase (167), β-glucosidase (72) and α-galactosidase (54). Zymography revealed presence of six cellulases, six mannanases and one β-glucosidase. It effectively degraded sugarcane bagasse (SCB) and rice straw (RS) releasing xylose, glucose and cellobiose. One cellulase (Cat 1, Mr ∼65 kDa) was purified and characterized. It retained more than 50% activity at 70 °C after 150 mins and its activity was enhanced in the presence of Mn²⁺ ions (130%) and β-mercaptoethanol (140%). FTIR and ¹³C CP/MAS NMR analysis of the enzyme treated SCB and RS revealed degradation of cellulose and hemicellulose, while ¹H and ¹³C liquid state NMR experiments confirmed release of glucose.

On-Site Production of Cellulolytic Enzymes by the Sequential Cultivation Method

The conversion of renewable lignocellulosic biomass into fuels, chemicals, and high-value materials using the biochemical platform has been considered the most sustainable alternative for the implementation of future biorefineries. However, the high cost of the cellulolytic enzymatic cocktails used in the saccharification step significantly affects the economics of industrial large-scale conversion processes. The on-site production of enzymes, integrated to the biorefinery plant, is being considered as a potential strategy that could be used to reduce costs. In such approach, the microbial production of enzymes can be carried out using the same lignocellulosic biomass as feedstock for fungal development and biofuels production. Most of the microbial cultivation processes for the production of industrial enzymes have been developed using the conventional submerged fermentation. Recently, a sequential solid-state followed by submerged fermentation has been described as a potential alternative cultivation method for cellulolytic enzymes production. This chapter presents the detailed procedure of the sequential cultivation method, which could be employed for the on-site production of the cellulolytic enzymes required to convert lignocellulosic biomass into simple sugars.