Production of fumaric acid by immobilized Rhizopus arrhizus RH 7-13-9# on loofah fiber in a stirred-tank reactor

Microbial biofilms as a platform for diverse biocatalytic applications

Microbial biofilms have gained significant traction in commercial wastewater treatment due to their inherent resilience, well-organized structure, and potential for collaborative metabolic processes. As our understanding of their physiology deepens, these living catalysts are finding exciting applications beyond wastewater treatment, including the production of bulk and fine chemicals, bioelectricity generation, and enzyme immobilization. While the biological applications of biofilms in different biocatalytic systems have been extensively summarized, the applications of artificially engineered biofilms were rarely discussed. This review aims to bridge this gap by highlighting the untapped potential of engineered microbial biofilms in diverse biocatalytic applications, with a focus on strategies for biofilms engineering. Strategies for engineering biofilm-based systems will be explored, including genetic modification, synthetic biology approaches, and targeted manipulation of biofilm formation processes. Finally, the review will address key challenges and future directions in developing robust biofilm-based biocatalytic platforms for large-scale production of chemicals, pharmaceuticals, and biofuels.

Microbial cell factories based on filamentous bacteria, yeasts, and fungi

BACKGROUND

Advanced DNA synthesis, biosensor assembly, and genetic circuit development in synthetic biology and metabolic engineering have reinforced the application of filamentous bacteria, yeasts, and fungi as promising chassis cells for chemical production, but their industrial application remains a major challenge that needs to be solved.

RESULTS

As important chassis strains, filamentous microorganisms can synthesize important enzymes, chemicals, and niche pharmaceutical products through microbial fermentation. With the aid of metabolic engineering and synthetic biology, filamentous bacteria, yeasts, and fungi can be developed into efficient microbial cell factories through genome engineering, pathway engineering, tolerance engineering, and microbial engineering. Mutant screening and metabolic engineering can be used in filamentous bacteria, filamentous yeasts (Candida glabrata, Candida utilis), and filamentous fungi (Aspergillus sp., Rhizopus sp.) to greatly increase their capacity for chemical production. This review highlights the potential of using biotechnology to further develop filamentous bacteria, yeasts, and fungi as alternative chassis strains.

CONCLUSIONS

In this review, we recapitulate the recent progress in the application of filamentous bacteria, yeasts, and fungi as microbial cell factories. Furthermore, emphasis on metabolic engineering strategies involved in cellular tolerance, metabolic engineering, and screening are discussed. Finally, we offer an outlook on advanced techniques for the engineering of filamentous bacteria, yeasts, and fungi.

Recent advances and perspectives on production of value-added organic acids through metabolic engineering

Organic acids are important consumable materials with a wide range of applications in the food, biopolymer and chemical industries. The global consumer organic acids market is estimated to increase to $36.86 billion by 2026. Conventionally, organic acids are produced from the chemical catalysis process with petrochemicals as raw materials, which posts severe environmental concerns and conflicts with our sustainable development goals. Most of the commonly used organic acids can be produced from various organisms. As a state-of-the-art technology, large-scale fermentative production of important organic acids with genetically-modified microbes has become an alternative to the chemical route to meet the market demand. Despite the fact that bio-based organic acid production from renewable cheap feedstock provides a viable solution, low productivity has impeded their industrial-scale application. With our deeper understanding of strain genetics, physiology and the availability of strain engineering tools, new technologies including synthetic biology, various metabolic engineering strategies, omics-based system biology tools, and high throughput screening methods are gradually established to bridge our knowledge gap. And they were further applied to modify the cellular reaction networks of potential microbial hosts and improve the strain performance, which facilitated the commercialization of consumable organic acids. Here we present the recent advances of metabolic engineering strategies to improve the production of important organic acids including fumaric acid, citric acid, itaconic acid, adipic acid, muconic acid, and we also discuss the current challenges and future perspectives on how we can develop a cost-efficient, green and sustainable process to produce these important chemicals from low-cost feedstocks.

State of the Art on the Microbial Production of Industrially Relevant Organic Acids

The industrial relevance of organic acids is high; because of their chemical properties, they can be used as building blocks as well as single-molecule agents with a huge annual market. Organic acid chemical platforms can derive from fossil sources by petrochemical refining processes, but most of them also represent natural metabolites produced by many cells. They are the products, by-products or co-products of many primary metabolic processes of microbial cells. Thanks to the potential of microbial cell factories and to the development of industrial biotechnology, from the last decades of the previous century, the microbial-based production of these molecules has started to approach the market. This was possible because of a joint effort of microbial biotechnologists and biochemical and process engineers that boosted natural production up to the titer, yield and productivity needed to be industrially competitive. More recently, the possibility to utilize renewable residual biomasses as feedstock not only for biofuels, but also for organic acids production is further augmenting the sustainability of their production, in a logic of circular bioeconomy. In this review, we briefly present the latest updates regarding the production of some industrially relevant organic acids (citric fumaric, itaconic, lactic and succinic acid), discussing the challenges and possible future developments of successful production.

Production of Fumaric Acid by Rhizopus arrhizus NRRL 1526: A Simple Production Medium and the Kinetic Modelling of the Bioprocess

Fumaric acid is a promising monomer to obtain biomass-based polyesters and polyamides, and it is mainly produced by fungi of the Rhizopus genus in medium to high titters. The use of glucose, a main component of starchy and cellulosic food waste, as carbon source, together with a low-nitrogen source concentration, is a promising route to reduce process costs. In this work, the effects of nitrogen and carbonate sources on Rhizopus arrhizus NRRL 1526 morphology and fumaric acid productivity were analysed, simplifying the traditional production broth composition. Moreover, a non-structured, non-segregated kinetic model was proposed and fitted to concentration data of all relevant components obtained in batches performed in triplicate with the selected production broth at 34 °C and 200 rpm in an orbital shaker.

Fumaric acid production using alternate fermentation mode by immobilized Rhizopus oryzae-a greener production strategy

The current work investigates the impact of using immobilized Rhizopus oryzae NRRL 1526 for bioproduction of fumaric acid using agro-industrial residues as feedstock. This use of agro-industrial residues, a renewable feedstock, for the production of bio-based platform chemical makes the process cost-competitive as well as greener by preventing the release of assimilable organic carbon to the environment, thereby reducing the generation of greenhouse gases. Immobilization of R. oryzae has been proposed previously to alleviate operational difficulties confronted during free mycelial fungal fermentation. To this effect, three synthetic refuse materials namely polystyrene foam, polyester sponge and polyurethane foam were investigated for their suitability towards fumaric acid bioproduction. Polystyrene foam was identified as the most suitable support material for immobilization as well as fumaric acid production. In addition to the considerable reduction in the lag-phase (from 48 to 24 h) the reduction in the size of the support material from cubes of 1 cm to beads of 0.1-0.3 cm led to a 42% improvement in fumaric acid production (27 g/L against 19 g/L). Growing the polystyrene foam bead immobilized R. oryzae on apple pomace ultrafiltration sludge as sole feedstock yielded a final fumaric acid titer of 7.9 g/L whereas free mycelial fermentation yielded 6.3 g/L. Moreover, upon operating the fermentation with intermittent feeding, a three-fold increase (1.7 g/L to 5.1 g/L) in fumaric acid production was obtained upon supplementation of the apple pomace sludge media with molasses, an agro-industrial residue, as feed.

Capability Enhancement of Fumaric Acid Production by Rhizopus arrhizus Through Carbon-Nitrogen Sources Coordination

Fumaric acid production from the fermentation process by Rhizopus was considered a potential method. But poor conversion efficiency and low space-time productivity greatly hampered industrial production. Here, we reported improving these problems through carbon-nitrogen sources coordination optimization strategy. Five commonly used nitrogen sources were selected to conduct element analysis and fermentation efficiency comparison. Casein was proven to be the optimum nitrogen source and further investigated in a stirred-tank reactor. It showed that the fermentation cycle was significantly shortened by the application of casein. Combined with optimization of glucose content, the space-time productivity of fumaric acid reached 0.76 g/L h with a yield to 0.31 g/g glucose, which was the highest among the results gotten in the stirred-tank reactor. It illustrated that carbon-nitrogen sources coordination optimization strategy was in favor of the improvement of the fermentation process and laid a promising foundation for the development of fumaric acid industrial production.

The Effectively Simultaneous Production of Cello-oligosaccharide and Glucose Mono-decanoate from Lignocellulose by Enzymatic Esterification

Cello-oligosaccharide has drawn an increasing attention as the nutritional ingredients of dietary supplements, whose quality is affected by the concentration of monosaccharide. In the present study, an effective process was developed for the simultaneous production of cello-oligosaccharide and glucose mono-decanoate from lignocellulose by enzymatic esterification. During the process, the excessive glucose in cello-oligosaccharide was converted into glucose mono-decanoate, which is a well-known biodegradable nonionic surfactant. The filter paper was initially used as the model to investigate the feasibility of the process, in which the purity of resultant cello-oligosaccharide was increased from 33.3% to 74.3%, simultaneously producing glucose mono-decanoate with a purity of 92.3%. Further verification of 3 kinds of lignocelluloses (switchgrass, cornstalk, and reed) also indicated a good performance of the process. The present process provided an effective strategy to increase the purity of resultant cello-oligosaccharide with the simultaneous production of high value-added products of sugar monoester. Graphical Abstract Simultaneous production of cello-oligosaccharide and glucose mono-decanoate from lignocellulose.

Engineering acetyl-CoA metabolic shortcut for eco-friendly production of polyketides triacetic acid lactone in Yarrowia lipolytica

Acetyl-CoA is the central metabolic node connecting glycolysis, Krebs cycle and fatty acids synthase. Plant-derived polyketides, are assembled from acetyl-CoA and malonyl-CoA, represent a large family of biological compounds with diversified bioactivity. Harnessing microbial bioconversion is considered as a feasible approach to large-scale production of polyketides from renewable feedstocks. Most of the current polyketide production platform relied on the lengthy glycolytic steps to provide acetyl-CoA, which inherently suffers from complex regulation with metabolically-costly cofactor/ATP requirements. Using the simplest polyketide triacetic acid lactone (TAL) as a testbed molecule, we demonstrate that acetate uptake pathway in oleaginous yeast (Yarrowia lipolytica) could function as an acetyl-CoA shortcut to achieve metabolic optimality in producing polyketides. We identified the metabolic bottlenecks to rewire acetate utilization for efficient TAL production in Y. lipolytica, including generation of the driving force for acetyl-CoA, malonyl-CoA and NADPH. The engineered strain, with the overexpression of endogenous acetyl-CoA carboxylase (ACC1), malic enzyme (MAE1) and a bacteria-derived cytosolic pyruvate dehydrogenase (PDH), affords robust TAL production with titer up to 4.76 g/L from industrial glacier acetic acid in shake flasks, representing 8.5-times improvement over the parental strain. The acetate-to-TAL conversion ratio (0.149 g/g) reaches 31.9% of the theoretical maximum yield. The carbon flux through this acetyl-CoA metabolic shortcut exceeds the carbon flux afforded by the native glycolytic pathways. Potentially, acetic acid could be manufactured in large-quantity at low-cost from Syngas fermentation or heterogenous catalysis (methanol carbonylation). This alternative carbon sources present a metabolic advantage over glucose to unleash intrinsic pathway limitations and achieve high carbon conversion efficiency and cost-efficiency. This work also highlights that low-cost acetic acid could be sustainably upgraded to high-value polyketides by oleaginous yeast species in an eco-friendly and cost-efficient manner.

Production of various organic acids from different renewable sources by immobilized cells in the regimes of separate hydrolysis and fermentation (SHF) and simultaneous saccharification and fermentation (SFF)

The study was aimed at production of different organic acids (OA) (lactic, fumaric, or succinic) by various microbial cells (filamentous fungi Rhizopus oryzae (F-814, F-1127) and bacteria Actinobacillus succinogenes B-10111) immobilized into poly(vinyl alcohol) (PVA) cryogel from diverse renewable raw materials (wheat and rice straw, aspen and pine sawdust, Jerusalem artichoke stems and tubers, biomass of macro- and microalgae) under batch conditions. The process productivity, bulk output and OA concentrations were higher in case of using immobilized cells than in case of free cells under identical conditions. A higher OA productivity was reached via simultaneous enzymatic saccharification and microbial fermentation (SSF) of same raw materials as compared to their separate enzymatic hydrolysis and fermentation of accumulated reducing sugars (SHF). Maximal concentrations of all OAs studied were obtained for bioconversion of Jerusalem artichoke tubers. The immobilized cells were used in long-term conversion of various renewable materials to OAs in SSF.

Fumaric acid: production and separation

Fumaric acid is a valuable compound used in foods, beverages, detergents, animal feed, pharmaceuticals and miscellaneous industrial products. It is produced on a large scale by the petrochemical route but the current tendency is towards implementing "green production" and environmental friendly technologies like biotechnological production of fumaric acid using low-cost raw materials. In this context, numerous studies focus on improving the fermentation process not only by using renewable raw material and genetically modified microorganisms, but also by developing and applying different downstream techniques for easy recovery of fumaric acid from the fermented broth. This review presents the main methods for production and separation of fumaric acid, highlighting the advantages and disadvantages of these and the potential economic impact in industry.

Genetic manipulation of Escherichia coli central carbon metabolism for efficient production of fumaric acid

Fumaric acid is one of the top 12-biomass building-block chemicals. In this study, we reported manipulation of E. coli central carbon metabolism with the aim to decrease the by-products and improve fumaric acid production. PEP-dependent glucose phosphotransferase system was replaced with a galactose translocation system to minimize the consumption of phosphoenolpyruvate. Engineering anaplerotic pathway (phosphoenolpyruvate carboxylase) was employed to redistribute carbon flux from glycolysis to Krebs cycle. Deletion of malate dehydrogenase and overexpression of acetyl-CoA synthase could decrease the byproducts malic acid and acetic acid. The combined strategies led to fumaric acid yield up to 1.53 g/g dry cell weight, a 50% increase compared with the parental strain. The result demonstrated that these genetic modifications were effective strategies for improving the production of fumaric acid and the engineered strain may serve a platform microbial cell factory for efficient production of fumaric acid or other dicarboxylic acids.