Microscale technology and biocatalytic processes: opportunities and challenges for synthesis

Biomimetic surfactants for tunable interfacial properties in drug delivery, biomedical coatings and tissue engineering

Biomimetic surfactants have emerged as a powerful class of interfacial agents designed to mimic biological amphiphiles, offering tunable physicochemical properties for drug delivery and biomedical coatings. This review explores the fundamental characteristics of biomimetic surfactants, comparing their advantages over synthetic and natural counterparts in modulating interfacial behaviors such as surface tension reduction, wettability control, and self-assembly into micellar structures. The role of surfactants in stabilizing lipid-based nanocarriers, polymer-surfactant hybrids, and bioinspired drug delivery systems is examined, highlighting their ability to enhance solubility, bioavailability, and targeted therapeutic delivery. Additionally, integrating surfactants into biomedical coatings has demonstrated significant potential in antifouling, antibacterial, and hemocompatible applications, crucial for implant safety, wound healing, and tissue engineering. Computational modeling, including molecular dynamics simulations, alongside experimental characterization techniques such as FTIR, DLS, TEM, and AFM, are pivotal in optimizing surfactant design for enhanced performance. Despite their promising applications, challenges remain in achieving stability, scalability, and regulatory approval for clinical translation. Future advancements in multifunctional and stimuli-responsive surfactants could revolutionize biomedical engineering, enabling next-generation drug delivery platforms and bioactive coatings. This review provides a comprehensive insight into the current progress, challenges, and future perspectives of biomimetic surfactants, paving the way for innovative and clinically viable solutions in biomedical applications.

Immobilisation for a stable biocatalyst application

This publication highlights the importance of immobilisation in obtaining stable biocatalysts. It is a review of the main immobilisation methods with their advantages and disadvantages. A distinction is made between methods that require a support (adsorption, covalent binding, binding via transition metals, entrapment/encapsulation) and those that do not (cross-linking, immobilisation in a reactor volume). The main characteristics that a material should have in order to be a suitable carrier for enzymes and the most popular carrier groups are discussed. The paper also highlights the factors that should be considered when designing an immobilisation methodology and the main parameters that characterise the immobilisation process. Attention is also given to the selection of a suitable reactor solution.

Flow fermentation: microsystems for whole-cell bioproduction processes

Industrial biotechnology utilizes whole cells for the production of value-added goods in large-scale bioreactors. The miniaturization of bioreactors has greatly contributed to the understanding and optimization of bioprocesses. However, microsystems for the production of value-added goods have thus far only been established in chemistry and biocatalysis/biotransformation but are rarely applied for whole-cell bioprocesses. Here, we discuss the fundamental and translational aspects of how microsystems could be used as production units for future whole-cell bioproduction processes. The characteristics and resulting advantages of microsystems are introduced and current production approaches are highlighted. Finally, we provide perspectives on establishing future whole-cell bioproduction processes at the microscale, here introduced as flow fermentation. Flow fermentation potentially enables entirely new bioprocesses and application fields.

Immobilization of His6-tagged amine transaminases in microreactors using functionalized nonwoven nanofiber membranes

Process intensification is crucial for industrial implementation of biocatalysis and can be achieved by continuous process operation in miniaturized reactors with efficiently immobilized biocatalysts, enabling their long-term use. Due to their extremely large surface-to-volume ratio, nanomaterials are promising supports for enzyme immobilization. In this work, different functionalized nanofibrous nonwoven membranes were embedded in a two-plate microreactor to enable immobilization of hexahistidine (His6)-tagged amine transaminases (ATAs) in flow. A membrane coated with Cu2+ ions gave the best results regarding His6-tagged ATAs immobilization among the membranes tested yielding an immobilization yield of up to 95.3 % for the purified N-His6-ATA-wt enzyme. Moreover, an efficient one-step enzyme immobilization process from overproduced enzyme in Escherichia coli cell lysate was developed and yielded enzyme loads up to 1088 U mL-1. High enzyme loads resulted in up to 80 % yields of acetophenone produced from 40 mM (S)-α-methylbenzylamine in less than 4 min using a continuously operated microreactor. Up to 81 % of the initial activity was maintained in a 5-day continuous microreactor operation with immobilized His6-tagged ATA constructs. The highest turnover number within the indicated time was 7.23·106, which indicates that this immobilization approach using advanced material and reactor system is highly relevant for industrial implementation.

Comprehensive Insights into Microbial Lipases: Unveiling Structural Dynamics, Catalytic Mechanism, and Versatile Applications

Microbial lipases (MLs) are pivotal biocatalysts in lipid biotechnology due to their diverse enzymatic properties and substrate specificity, garnering significant research attention. This comprehensive review explores the significance of MLs in biocatalysis, providing insights into their structure, catalytic domain, and oxyanion hole. The catalytic mechanism is elucidated, highlighting the molecular processes driving their efficiency. The review delves into ML sources, spanning fungi, yeasts, bacteria, and actinomycetes, followed by a discussion on classification and characterization. Emphasizing the scattered findings in the literature, the paper consolidates the latest information on ML applications across various industries, from food and pharmaceuticals to biofuel production and the paper and pulp industry. The review captures the dynamic landscape of ML research, emphasizing their structure-function relationships and practical implications across diverse sectors.

Development of a Microbioreactor for Bacillus subtilis Biofilm Cultivation

To improve our understanding of Bacillus subtilis growth and biofilm formation under different environmental conditions, two versions of a microfluidic reactor with two channels separated by a polydimethylsiloxane (PDMS) membrane were developed. The gas phase was introduced into the channel above the membrane, and oxygen transfer from the gas phase through the membrane was assessed by measuring the dissolved oxygen concentration in the liquid phase using a miniaturized optical sensor and oxygen-sensitive nanoparticles. B. subtilis biofilm formation was monitored in the growth channels of the microbioreactors, which were designed in two shapes: one with circular extensions and one without. The volumes of these microbioreactors were (17 ± 4) μL for the reactors without extensions and (28 ± 4) μL for those with extensions. The effect of microbioreactor geometry and aeration on B. subtilis biofilm growth was evaluated by digital image analysis. In both microbioreactor geometries, stable B. subtilis biofilm formation was achieved after 72 h of incubation at a growth medium flow rate of 1 μL/min. The amount of oxygen significantly influenced biofilm formation. When the culture was cultivated with a continuous air supply, biofilm surface coverage and biomass concentration were higher than in cultivations without aeration or with a 100% oxygen supply. The channel geometry with circular extensions did not lead to a higher total biomass in the microbioreactor compared to the geometry without extensions.

Biocatalyst for the synthesis of natural flavouring compounds as food additives: Bridging the gap for a more sustainable industrial future

Biocatalysis entails the use of purified enzymes in the manufacturing of flavouring chemicals food industry as well as at the laboratory level. These biocatalysts can significantly accelerate organic chemical processes and improve product stereospecificity. The unique characteristics of biocatalyst helpful in synthesizing the environmentally friendly flavour and aroma compounds used as a food additive in foodstuffs. With methods like enzyme engineering on biotechnological interventions the efficient tuning of produce will fulfil the needs of food industry. This review summarizes the biosynthesis of different flavour and aroma component through microbial catalysts and using advanced techniques which are available for enzyme improvement. Also pointing out their benefits and drawbacks for specific technological processes necessary for successful industrial application of biocatalysts. The article covers the market scenario, cost economics, environmental safety and regulatory framework for the production of food flavoured chemicals by the bioprocess engineering.

Microreactor Technology: Identifying Focus Fields and Emerging Trends by Using CiteSpace II

Microreactors have gained widespread attention from academia and industrial researchers due to their exceptionally fast mass and heat transfer and flexible control. In this work, CiteSpace software was used to systematically analyze the relevant literature to gain a comprehensively understand on the research status of microreactors in various fields. The results show that the research depth and application scope of microreactors are continuing to expand. The top 10 most popular research fields are photochemistry, pharmaceutical intermediates, multistep flow synthesis, mass transfer, computational fluid dynamics, μ-TAS (micro total analysis system), nanoparticles, biocatalysis, hydrogen production, and solid-supported reagents. The evolution trends of current focus areas are examined, including photochemistry, mass transfer, biocatalysis and hydrogen production and their milestone literature is analyzed in detail. This article demonstrates the development of different fields of microreactors technology and highlights the unending opportunities and challenges offered by this fascinating technology.

Is enzyme immobilization a mature discipline? Some critical considerations to capitalize on the benefits of immobilization

Enzyme immobilization has been developing since the 1960s and although many industrial biocatalytic processes use the technology to improve enzyme performance, still today we are far from full exploitation of the field. One clear reason is that many evaluate immobilization based on only a few experiments that are not always well-designed. In contrast to many other reviews on the subject, here we highlight the pitfalls of using incorrectly designed immobilization protocols and explain why in many cases sub-optimal results are obtained. We also describe solutions to overcome these challenges and come to the conclusion that recent developments in material science, bioprocess engineering and protein science continue to open new opportunities for the future. In this way, enzyme immobilization, far from being a mature discipline, remains as a subject of high interest and where intense research is still necessary to take full advantage of the possibilities.

Alginate@polydopamine@SiO2 microcapsules with controlled porosity for whole-cell based enantioselective biosynthesis of (S)-1-phenylethanol

Whole-cell biocatalysis, owing to its high enantioselectivity, environment friendly and mild reaction condition, show a great prospect in chemical, pharmaceutical and fuel industry. However, several problems still limit its wide applications, mainly concerning the low productivity and poor stability. Although the biocatalyst encapsulated in the most-commonly-used alginate hydrogels demonstrate enhanced stability, it still suffers from low biocatalytic productivity, long-term reusability and poor mass diffusion control. In this work, hybrid alginate@polydopamine@SiO₂ microcapsules with controlled porosity are designed to encapsulate yeast cells for the asymmetric biosynthesis of (S)- 1-phenylethonal from acetophenone. The hybrid microcapsules are formed by the ionic cross-linking of alginate, the polymerization of dopamine monomers and the protamine-assisted colloidal packing of uniform-sized silica nanoparticles. Alginate provides the encapsulated cells with highly biocompatible environment. Polydopamine enables to stimulate the biocatalytic productivity of the encapsulated yeast cells. Silica shells can not only regulate the mass diffusion in biocatalysis but also enhance the long-term mechanical and chemical stability of the microcapsules. The morphology, structure, chemical composition, stability and molecular accessibility of the hybrid microcapsules are investigated in detail. The viability and asymmetric bioreduction performance of the cells encapsulated in microcapsules are evaluated. The 24 h product yield of the cells encapsulated in the hybrid microcapsules shows 1.75 times higher than that of the cells encapsulated in pure alginate microcapsules. After 6 batches, the 24 h product yield of the cells encapsulated in the hybrid microcapsules is well maintained and 2 times higher than that of the cells encapsulated in pure alginate microcapsules. Therefore, the hybrid microcapsules designed in this study enable to enhance the asymmetric biocatalytic activity, stability and reusability of the encapsulated cells, thus contributing to a significant progress in cell-encapsulating materials to be applied in biocatalytic asymmetric synthesis industry.

Integrating Biocatalysis with Viscous Deep Eutectic Solvents in Lab-On-A-Chip Microreactors

The combination of deep eutectic solvents (DESs, ChCl/glycerol 1 : 2) with buffer (up to 15 % v/v) leads to solvent mixtures that exert viscosities below 25 mPa s^-1 at 45 °C while keeping their non-aqueous nature. This enables the setup of efficient enzymatic esterifications, which can also be applied in different continuous systems. Following those premises, the use of microreactors in biocatalytic reactions was explored using (low-viscous) DES-buffer media, showing that reactions could be performed efficiently. Under non-optimized conditions, the microreactor devices led to specific productivities considerably higher than those observed in the batch reactor (14 vs. 0.24 mg_product  min^-1  mg_biocat ^-1 ) at the same enzyme loadings and conversion of 6 % (to assure a fair comparison). Looking beyond, the combination of several microchannels (e. g., in scale-out fashion) with DES-water media may lead to powerful, sustainable, and efficient tools for industrial synthesis.

Glycosylation-on-a-Chip: A Flow-Based Microfluidic System for Cell-Free Glycoprotein Biosynthesis

In recent years, cell-free synthetic glycobiology technologies have emerged that enable production and remodeling of glycoproteins outside the confines of the cell. However, many of these systems combine multiple synthesis steps into one pot where there can be competing reactions and side products that ultimately lead to low yield of the desired product. In this work, we describe a microfluidic platform that integrates cell-free protein synthesis, glycosylation, and purification of a model glycoprotein in separate compartments where each step can be individually optimized. Microfluidics offer advantages such as reaction compartmentalization, tunable residence time, the ability to tether enzymes for reuse, and the potential for continuous manufacturing. Moreover, it affords an opportunity for spatiotemporal control of glycosylation reactions that is difficult to achieve with existing cell-based and cell-free glycosylation systems. In this work, we demonstrate a flow-based glycoprotein synthesis system that promotes enhanced cell-free protein synthesis, efficient protein glycosylation with an immobilized oligosaccharyltransferase, and enrichment of the protein product from cell-free lysate. Overall, this work represents a first-in-kind glycosylation-on-a-chip prototype that could find use as a laboratory tool for mechanistic dissection of the protein glycosylation process as well as a biomanufacturing platform for small batch, decentralized glycoprotein production.

A review of synthesis of esters with aromatic, emulsifying, and lubricant properties by biotransformation using lipases

The esterification reactions catalyzed by lipases are among the most significant biochemical processes of industrial relevance. The lipases have the function of versatility by catalyzing a diversity of reactions with extreme ease, obtaining quality products with high yield. Therefore, enzyme-catalyzed esterification has gained increasing attention in many applications, due to the importance of derived products. More specifically, lipase-catalyzed esterification reactions have attracted interest in research over the past decade, due to the increased use of organic esters in the chemical and biotechnology industry. These esters can be obtained by three techniques: extraction from natural sources, chemical and enzymatic syntheses. Biotechnological processes have offered several advantages and are shown as a competitive alternative to chemical methods due to high catalytic efficiency, mild operating conditions, and selectivity of natural catalysts. These an industrial point of view, reactions catalyzed by enzymes are the most economical approach to achieve green products with no toxicity and no harm to human health. Thus, this review presents a descriptive evaluation of the trends and perspectives applied to enzymatic esterification, mainly for the synthesis of esters with different properties, such as aromatics, emulsifiers, and lubricants using the esterification process. An emphasis is given to essential factors, which affect the lipase-catalyzed esterification reaction. In which, the parameters dependent on the lipase source, a form of the biocatalyst (free or immobilized), the polarity of the reaction medium, the molar ratio between alcohol and acid, among other variables, are also discussed. This article is protected by copyright. All rights reserved.

Hydrogel-Based Enzyme and Cofactor Co-Immobilization for Efficient Continuous Transamination in a Microbioreactor

A microbioreactor was developed in which selected amine transaminase was immobilized together with the cofactor pyridoxal phosphate (PLP) to allow efficient continuous transamination. The enzyme and cofactor were retained in a porous copolymeric hydrogel matrix formed in a two-plate microreactor with an immobilization efficiency of over 97%. After 10 days of continuous operation, 92% of the initial productivity was retained and no leaching of PLP or enzyme from the hydrogel was observed. The microbioreactor with co-immobilized cofactor showed similar performance with and without the addition of exogenous PLP, suggesting that the addition of PLP is not required during the process. The space-time yield of the microbioreactor was 19.91 g L⁻¹ h⁻¹, while the highest achieved biocatalyst productivity was 5.4 mg mg_enzyme⁻¹ h⁻¹. The immobilized enzyme also showed better stability over a wider pH and temperature range than the free enzyme. Considering the time and cost efficiency of the immobilization process and the possibility of capacity expansion, such a system is of great potential for industrial application.

Two-Phase Biocatalysis in Microfluidic Droplets

This Perspective discusses the literature related to two-phase biocatalysis in microfluidic droplets. Enzymes used as catalysts in biocatalysis are generally less stable in organic media than in their native aqueous environments; however, chemical and pharmaceutical compounds are often insoluble in water. The use of aqueous/organic two-phase media provides a solution to this problem and has therefore become standard practice for multiple biotransformations. In batch, two-phase biocatalysis is limited by mass transport, a limitation that can be overcome with the use of microfluidic systems. Although, two-phase biocatalysis in laminar flow systems has been extensively studied, microfluidic droplets have been primarily used for enzyme screening. In this Perspective, we summarize the limited published work on two-phase biocatalysis in microfluidic droplets and discuss the limitations, challenges, and future perspectives of this technology.

Development of an electrically responsive hydrogel for programmable in situ immobilization within a microfluidic device

A novel microfluidic channel device with programmable in situ formation of a hydrogel 3D network was designed. A biocompatible hybrid material consisting of iron ion-crosslinked alginate was used as the active porous medium. The sol-gel transition of the alginate was controlled by the oxidation state of Fe ions and regulated by an external electrical signal through an integrated gold plate electrode. The SEM images, FT-IR analysis, and rheological test demonstrated that homogeneous yet programmable hydrogel films were formed. The higher the concentration of the crosslinker (Fe(iii)), the smaller the pore and mesh size of the hydrogel. Moreover, the hydrogel thickness and volume were tailored by controlling the deposition time and the strength of electric current density. The as-prepared system was employed as an active medium for immobilization of target molecules, using BSA as a drug-mimicking protein. The reductive potential (activated by switching the current direction) caused dissolution of the hydrogel and consequently the release of BSA and Fe. The diffusion of the entrapped molecules was optimally adjusted by varying the dissolution conditions and the initial formulations. Finally, the altering electrical conditions confirm the programmable nature of the electrically responsive material and highlight its wide-ranging application potential.

Multi-Enzyme Systems in Flow Chemistry

Recent years have witnessed a growing interest in the use of biocatalysts in flow reactors. This merging combines the high selectivity and mild operation conditions typical of biocatalysis with enhanced mass transfer and resource efficiency associated to flow chemistry. Additionally, it provides a sound environment to emulate Nature by mimicking metabolic pathways in living cells and to produce goods through the systematic organization of enzymes towards efficient cascade reactions. Moreover, by enabling the combination of enzymes from different hosts, this approach paves the way for novel pathways. The present review aims to present recent developments within the scope of flow chemistry involving multi-enzymatic cascade reactions. The types of reactors used are briefly addressed. Immobilization methodologies and strategies for the application of the immobilized biocatalysts are presented and discussed. Key aspects related to the use of whole cells in flow chemistry are presented. The combination of chemocatalysis and biocatalysis is also addressed and relevant aspects are highlighted. Challenges faced in the transition from microscale to industrial scale are presented and discussed.

Flow Biocatalysis: A Challenging Alternative for the Synthesis of APIs and Natural Compounds

Biocatalysts represent an efficient, highly selective and greener alternative to metal catalysts in both industry and academia. In the last two decades, the interest in biocatalytic transformations has increased due to an urgent need for more sustainable industrial processes that comply with the principles of green chemistry. Thanks to the recent advances in biotechnologies, protein engineering and the Nobel prize awarded concept of direct enzymatic evolution, the synthetic enzymatic toolbox has expanded significantly. In particular, the implementation of biocatalysts in continuous flow systems has attracted much attention, especially from industry. The advantages of flow chemistry enable biosynthesis to overcome well-known limitations of “classic” enzymatic catalysis, such as time-consuming work-ups and enzyme inhibition, as well as difficult scale-up and process intensifications. Moreover, continuous flow biocatalysis provides access to practical, economical and more sustainable synthetic pathways, an important aspect for the future of pharmaceutical companies if they want to compete in the market while complying with European Medicines Agency (EMA), Food and Drug Administration (FDA) and green chemistry requirements. This review focuses on the most recent advances in the use of flow biocatalysis for the synthesis of active pharmaceutical ingredients (APIs), pharmaceuticals and natural products, and the advantages and limitations are discussed.

Process Intensification Approach Using Microreactors for Synthesizing Nanomaterials-A Critical Review

Nanomaterials have found many applications due to their unique properties such as high surface-to-volume ratio, density, strength, and many more. This review focuses on the recent developments on the synthesis of nanomaterials using process intensification. The review covers the designing of microreactors, design principles, and fundamental mechanisms involved in process intensification using microreactors for synthesizing nanomaterials. The microfluidics technology operates in continuous mode as well as the segmented flow of gas–liquid combinations. Various examples from the literature are discussed in detail highlighting the advantages and disadvantages of microfluidics technology for nanomaterial synthesis.

Enzymatic electrochemical continuous flow cascade synthesis of substituted benzimidazoles

An industrially practical method for the synthesis of substituted benzimidazoles was developed from an enzymatic electrochemical cascade method.

Development of a continuous-flow system with immobilized biocatalysts towards sustainable bioprocessing

Implementing immobilized biocatalysts in continuous-flow systems can enable a sustainable process through enhanced enzyme stability, better transport and process continuity as well as simplified recycle and downstream processing.

Process intensification using immobilized enzymes for the development of white biotechnology

Process intensification of biocatalysed reactions using different techniques such as microwaves, ultrasound, hydrodynamic cavitation, ionic liquids, microreactors and flow chemistry in various industries is critically analysed and future directions provided.

Recent developments in microreactor technology for biocatalysis applications

Through the use of microfluidics technology, one can severely accelerate the development and optimization of biocatalytic processes. In this work, the authors present a comprehensive review of the recent advances in the field.

Development of a Microfluidic Platform for R-Phycoerythrin Purification Using an Aqueous Micellar Two-Phase System

Temperature-dependent aqueous micellar two-phase systems (AMTPSs) have recently been gaining attention in the isolation of high-added-value biomolecules from their natural sources. Despite their sustainability, aqueous two-phase systems, and particularly AMTPSs, have not been extensively applied in the industry, which might be changed by applying process integration and continuous manufacturing. Here, we report for the first time on an integrated microfluidic platform for fast and low-material-consuming development of continuous protein purification using an AMTPS. A system comprised of a microchannel incubated at high temperature, enabling instantaneous triggering of a two-phase system formation, and a microsettler, allowing complete phase separation at the outlets, is reported here. The separation of phycobiliproteins and particularly the purification of R-phycoerythrin from the contaminant proteins present in the aqueous crude extract obtained from fresh cells of Gracilaria gracilis were thereby achieved. The results from the developed microfluidic system revealed that the fractionation performance was maintained while reducing the processing time more than 20-fold when compared with the conventional lab-scale batch process. Furthermore, the integration of a miniaturized ultrafiltration module resulted in the complete removal of the surfactant from the bottom phase containing R-phycoerythrin, as well as in nearly twofold target protein concentration. The process setup successfully exploits the benefits of process intensification along with the integration of various downstream processes. Further transfer to a meso-scale integrated system would make such a system appropriate for the separation and purification of biomolecules with high commercial interest.

Enzymatic Bioreactors: An Electrochemical Perspective

Biocatalysts provide a number of advantages such as high selectivity, the ability to operate under mild reaction conditions and availability from renewable resources that are of interest in the development of bioreactors for applications in the pharmaceutical and other sectors. The use of oxidoreductases in biocatalytic reactors is primarily focused on the use of NAD(P)-dependent enzymes, with the recycling of the cofactor occurring via an additional enzymatic system. The use of electrochemically based systems has been limited. This review focuses on the development of electrochemically based biocatalytic reactors. The mechanisms of mediated and direct electron transfer together with methods of immobilising enzymes are briefly reviewed. The use of electrochemically based batch and flow reactors is reviewed in detail with a focus on recent developments in the use of high surface area electrodes, enzyme engineering and enzyme cascades. A future perspective on electrochemically based bioreactors is presented.

Biocatalysis - Key enabling tools from biocatalytic one-step and multi-step reactions to biocatalytic total synthesis

In the area of human-made innovations to improve the quality of life, biocatalysis has already had a great impact and contributed enormously to a growing number of catalytic transformations aimed at the detection and analysis of compounds, the bioconversion of starting materials and the preparation of target compounds at any scale, from laboratory small scale to industrial large scale. The key enabling tools which have been developed in biocatalysis over the last decades also provide great opportunities for further development and numerous applications in various sectors of the global bioeconomy. Systems biocatalysis is a modular, bottom-up approach to designing the architecture of enzyme-catalyzed reaction steps in a synthetic route from starting materials to target molecules. The integration of biocatalysis and sustainable chemistry in vitro aims at ideal conversions with high molecular economy and their intensification. Retrosynthetic analysis in the chemical and biological domain has been a valuable tool for target-oriented synthesis while, on the other hand, diversity-oriented synthesis builds on forward-looking analysis. Bioinformatic tools for rapid identification of the required enzyme functions, efficient enzyme production systems, as well as generalized bioprocess design tools, are important for rapid prototyping of the biocatalytic reactions. The tools for enzyme engineering and the reaction engineering of each enzyme-catalyzed one-step reaction are also valuable for coupling reactions. The tools to overcome interaction issues with other components or enzymes are of great interest in designing multi-step reactions as well as in biocatalytic total synthesis.

Design, Fundamental Principles of Fabrication and Applications of Microreactors

This study highlights the development of small-scale reactors, in the form of microstructures with microchannel networking. Microreactors have achieved an impressive reputation, regarding chemical synthesis ability and their applications in the engineering, pharmaceutical, and biological fields. This review elaborates on the fabrication, construction, and schematic fundamentals in the design of the microreactors and microchannels. The materials used in the fabrication or construction of the microreactors include silicon, polymer, and glass. A general review of the application of microreactors in medical, biological, and engineering fields is carried out and significant improvements in these areas are reported. Finally, we highlight the flow patterns, mixing, and scaling-up of multiphase microreactor developments, with emphasis on the more significant industrial applications.

Covalent Immobilization of Microbial Cells on Microchannel Surfaces

Microfluidic devices with integrated biological material have found many applications in analytics (e.g., protein and DNA analysis), biochemistry (e.g., PCR), and medical diagnostics (e.g., ELISA test). Recently they are also considered as promising tools for bioprocess development and intensification. In order to enable long-term biocatalyst use and to facilitate its separation from the product, immobilization within the microreactor is often preferred over the use of free enzymes or cells. Surface immobilization is frequently selected due to the very high surface-to-volume ratio of microfluidic devices that offers the possibility for high biocatalyst load and at the same time good biocatalyst accessibility. Moreover, such reactor design prevents the increase in backpressure, often encountered in packed-bed or monolithic microreactors.Microbial cells are beneficial over the isolated enzymes in many biotransformations, especially in multistep syntheses and in cofactor-dependent reactions. Their immobilization within microreactors, especially made from disposable polymers, is of a big interest for analytical and synthetic applications.This chapter describes procedure for immobilization of eukaryotic and prokaryotic cells onto inner surfaces of microreactors made from various polymeric materials and glass. Cells could be immobilized in high densities and remain stably attached over several days of continuous microreactor operation.

Improvement of silver azide crystal morphology and detonation behavior by fast mixing using a microreaction system with an integrated static micromixer

A continuous microreaction system with an integrated passive micromixer is developed to optimize the crystal morphology and detonation behavior of AgN₃.

Enzyme Immobilization in Wall-Coated Flow Microreactors

Flow microreactors are emergent engineering tools for the development of continuous biocatalytic transformations. Exploiting enzymes in continuous mode requires their retention for multiple rounds of conversions. To achieve this goal, immobilizing the enzymes on microchannel walls is a promising approach. However, protein immobilization within closed structures is difficult. Here, we describe a methodology based on the confluent design of enzyme and microreactor; fusion to the silica-binding module Z_basic2 is used to engineer enzymes for high-affinity-oriented attachment to the plain wall surface of glass microchannels. As a practical case, the methodology is described using a sucrose phosphorylase; the assayed reaction is synthesis of α-D-glucose 1-phosphate (αGlc 1-P) from sucrose and phosphate using the immobilized enzyme microreactor. Procedures of enzyme immobilization, reactor characterization, and operation are described. The methodology is applicable for any other enzymes fused to Z_basic2 and silica (glass)-based microfluidic reactors.

The rise of continuous flow biocatalysis – fundamentals, very recent developments and future perspectives

Very recent developments in the field of biocatalysis in continuously operated systems. Special attention on the future perspectives in this key emerging technological area ranging from process analytical technologies to digitalization.

Theoretical study on enzyme synthesis of cephalexin in a parallel-flow microreactor combined with electrically driven ATPS microextraction

A mathematical model of a microfluidic device with two aqueous phases for the simultaneous cephalexin production and its separation from a reaction mixture was developed. The model anticipates the continuous cephalexin synthesis and enzyme recyclation.

Copolymeric Hydrogel-Based Immobilization of Yeast Cells for Continuous Biotransformation of Fumaric Acid in a Microreactor

Although enzymatic microbioreactors have recently gained lots of attention, reports on the use of whole cells as biocatalysts in microreactors have been rather modest. In this work, an efficient microreactor with permeabilized Saccharomyces cerevisiae cells was developed and used for continuous biotransformation of fumaric into industrially relevant L-malic acid. The immobilization of yeast cells was achieved by entrapment in a porous structure of various hydrogels. Copolymers based on different ratios of sodium alginate (SA) and polyvinyl alcohol (PVA) were used for hydrogel formation, while calcium chloride and boric or phenylboronic acid were tested as crosslinking agents for SA and PVA, respectively. The influence of hydrogel composition on physico-chemical properties of hydrogels prepared in the form of thin films was evaluated. Immobilization of permeabilized S. cerevisiae cells in the selected copolymeric hydrogel resulted in up to 72% retained fumarase activity. The continuous biotransformation process using two layers of hydrogels integrated into a two-plate microreactor revealed high space time yield of 2.86 g/(L·h) while no activity loss was recorded during 7 days of continuous operation.

Imine Reductase Based All-Enzyme Hydrogel with Intrinsic Cofactor Regeneration for Flow Biocatalysis

All-enzyme hydrogels are biocatalytic materials, with which various enzymes can be immobilized in microreactors in a simple, mild, and efficient manner to be used for continuous flow processes. Here we present the construction and application of a cofactor regenerating hydrogel based on the imine reductase GF3546 from Streptomyces sp. combined with the cofactor regenerating glucose-1-dehydrogenase from Bacillus subtilis. The resulting hydrogel materials were characterized in terms of binding kinetics and viscoelastic properties. The materials were formed by rapid covalent crosslinking in less than 5 min, and they showed a typical mesh size of 67 ± 2 nm. The gels were applied for continuous flow biocatalysis. In a microfluidic reactor setup, the hydrogels showed excellent conversions of imines to amines for up to 40 h in continuous flow mode. Variation of flow rates led to a process where the gels showed a maximum space-time-yield of 150 g·(L·day)-1 at 100 μL/min.

Valency engineering of monomeric enzymes for self-assembling biocatalytic hydrogels

All-enzyme hydrogels are efficient reagents for continuous flow biocatalysis. These materials can be obtained by self-assembly of two oligomeric enzymes, modified with the complementary SpyTag and SpyCatcher units. To facilitate access to the large proportion of biocatalytically relevant monomeric enzymes, we demonstrate that the tagging valency of the monomeric (S)-stereoselective ketoreductase Gre2p from Saccharomyces cerevisiae can be designed to assemble stable, active hydrogels with the cofactor-regenerating glucose 1-dehydrogenase GDH from Bacillus subtilis. Mounted in microfluidic reactors, these gels revealed high conversion rates and stereoselectivity in the reduction of prochiral methylketones under continuous flow for more than 8 days. The sequential use as well as parallelization by 'numbering up' of the flow reactor modules demonstrate that this approach is suitable for syntheses on the semipreparative scale.

Leloir Glycosyltransferases in Applied Biocatalysis: A Multidisciplinary Approach

Enzymes are nature’s catalyst of choice for the highly selective and efficient coupling of carbohydrates. Enzymatic sugar coupling is a competitive technology for industrial glycosylation reactions, since chemical synthetic routes require extensive use of laborious protection group manipulations and often lack regio- and stereoselectivity. The application of Leloir glycosyltransferases has received considerable attention in recent years and offers excellent control over the reactivity and selectivity of glycosylation reactions with unprotected carbohydrates, paving the way for previously inaccessible synthetic routes. The development of nucleotide recycling cascades has allowed for the efficient production and reuse of nucleotide sugar donors in robust one-pot multi-enzyme glycosylation cascades. In this way, large glycans and glycoconjugates with complex stereochemistry can be constructed. With recent advances, LeLoir glycosyltransferases are close to being applied industrially in multi-enzyme, programmable cascade glycosylations.

Broadening the Scope of Biocatalysis in Sustainable Organic Synthesis

This Review is aimed at synthetic organic chemists who may be familiar with organometallic catalysis but have no experience with biocatalysis, and seeks to provide an answer to the perennial question: if it is so attractive, why wasn't it extensively used in the past? The development of biocatalysis in industrial organic synthesis is traced from the middle of the last century. Advances in molecular biology in the last two decades, in particular genome sequencing, gene synthesis and directed evolution of proteins, have enabled remarkable improvements in scope and substantially reduced biocatalyst development times and cost contributions. Additionally, improvements in biocatalyst recovery and reuse have been facilitated by developments in enzyme immobilization technologies. Biocatalysis has become eminently competitive with chemocatalysis and the biocatalytic production of important pharmaceutical intermediates, such as enantiopure alcohols and amines, has become mainstream organic synthesis. The synthetic space of biocatalysis has significantly expanded and is currently being extended even further to include new-to-nature biocatalytic reactions.