Development of a Circular Oriented Bioprocess for Microbial Oil Production Using Diversified Mixed Confectionery Side-Streams

Unlocking the potential of spent coffee grounds via a comprehensive biorefinery approach: production of microbial oil and carotenoids under fed-batch fermentation

The valorization of renewable feedstock to produce a plethora of value-added products could promote the transition towards a circular bioeconomy. This study presents the development of cascade processes to bioconvert spent coffee grounds (SCGs) into microbial oil and carotenoids employing sustainable practices. The stepwise recovery of crude phenolic extract and coffee oil was carried out using green or recyclable solvents, i.e., aqueous ethanol and hexane. Palmitic acid (43.3%) and linoleic acid (38.9%) were the major fatty acids in the oil fraction of SCGs. The LC-MS analysis of crude phenolic extracts revealed that chlorogenic acid dominated (45.7%), while neochlorogenic acid was also detected in substantial amounts (24.0%). SCGs free of coffee oil and phenolic compounds were subjected to microwave-assisted pretreatment under different irradiations and solvents to enhance subsequent enzymatic saccharification. Microwave/water pretreatment at 400 W, followed by enzymatic hydrolysis with proteases, hemicellulases, and cellulases, at 50 g/L initial SCGs, led to satisfying overall yields of cellulose (75.4%), hemicellulose (50.3%), and holocellulose (55.3%). Mannan was the most extractable polysaccharide followed by galactan and arabinan. SCGs hydrolysate was used in fed-batch bioreactor fermentations with Rhodosporidium toruloides to produce 24.0 g/L microbial oil and carotenoids of 432.9 μg/g biomass.

Sustainable Food Systems: The Case of Functional Compounds towards the Development of Clean Label Food Products

The addition of natural components with functional properties in novel food formulations confers one of the main challenges that the modern food industry is called to face. New EU directives and the global turn to circular economy models are also pressing the agro-industrial sector to adopt cradle-to-cradle approaches for their by-products and waste streams. This review aims to present the concept of “sustainable functional compounds”, emphasizing on some main bioactive compounds that could be recovered or biotechnologically produced from renewable resources. Herein, and in view of their efficient and “greener” production and extraction, emerging technologies, together with their possible advantages or drawbacks, are presented and discussed. Μodern examples of novel, clean label food products that are composed of sustainable functional compounds are summarized. Finally, some action plans towards the establishment of sustainable food systems are suggested.

Coproduction of Microbial Oil and Carotenoids within the Circular Bioeconomy Concept: A Sequential Solid-State and Submerged Fermentation Approach

The main objective of integrative biorefinery platforms is to propose efficient green methodologies addressed to obtain high-value compounds with low emissions through biochemical conversions. This work first screened the capacity of various oleaginous yeast to cosynthesize high-value biomolecules such as lipids and carotenoids. Selected strains were evaluated for their ability to coproduce such biocompounds in the waste-based media of agro-food (brewer’s spent grain, pasta processing waste and bakery waste). Carbon and nitrogen source feedstock was obtained through enzymatic hydrolysis of the agro-food waste, where up to 80% of total sugar/starch conversion was obtained. Then, the profitability of the bioprocess for microbial oil (MO) and carotenoids production by Sporobolomyces roseus CFGU-S005 was estimated via simulation using SuperPro Designer®. Results showed the benefits of establishing optimum equipment scheduling by identifying bottlenecks to increase profitability. Sensitivity analysis demonstrated the impact of MO price and batch throughput on process economics. A profitable process was achieved with a MO batch throughput of 3.7 kg/batch (ROI 31%, payback time 3.13 years). The results revealed areas that require further improvement to achieve a sustainable and competitive process for the microbial production of carotenoids and lipids.

Efficient and Fast Removal of Oils from Water Surfaces via Highly Oleophilic Polyurethane Composites

In this study we evaluated the oil adsorption capacity of an aliphatic polyurethane foam (PU 1) and two of its composites, produced through surface coating using microparticles of silica (PU-Si 2) and activated carbon (PU-ac 3). The oil adsorption capacity in diesel was improved up to 36% using the composite with silica and up to 50% using the composite with activated carbon with respect to the initial PU 1. Excellent performances were retained in gasoline and motor oil. The adsorption was complete after a few seconds. The process follows a monolayer adsorption fitted by the Langmuir isotherm, with a maximum adsorption capacity of 29.50 g/g of diesel for the composite with activated carbon (PU-ac 3). These materials were proved to be highly oleophilic for oil removal from fresh water and sea water samples. Regeneration and reuse can be repeated up to 50 times by centrifugation, without a significant loss in adsorption capacity.

Valorization of Greenhouse Horticulture Waste from a Biorefinery Perspective

Greenhouse cultivation and harvesting generate considerable amounts of organic waste, including vegetal waste from plants and discarded products. This study evaluated the residues derived from tomato cultivation practices in Almería (Spain) as sugar-rich raw materials for biorefineries. First, lignocellulose-based residues were subjected to an alkali-catalyzed extrusion process in a twin-screw extruder (100 °C and 6–12% (w/w) NaOH) to assess maximum sugar recovery during the subsequent enzymatic hydrolysis step. A high saccharification yield was reached when using an alkali concentration of 12% (w/w), releasing up to 81% of the initial glucan. Second, the discarded tomato residue was crushed and centrifuged to collect both the juice and the pulp fractions. The juice contained 39.4 g of sugars per 100 g of dry culled tomato, while the pulp yielded an extra 9.1 g of sugars per 100 g of dry culled tomato after an enzymatic hydrolysis process. The results presented herein show the potential of using horticulture waste as an attractive sugar source for biorefineries, including lignocellulose-based residues when effective fractionation processes, such as reactive extrusion technology, are available.

Oleaginous Yeasts as Cell Factories for the Sustainable Production of Microbial Lipids by the Valorization of Agri-Food Wastes

The agri-food industry annually produces huge amounts of crops residues and wastes, the suitable management of these products is important to increase the sustainability of agro-industrial production by optimizing the entire value chain. This is also in line with the driving principles of the circular economy, according to which residues can become feedstocks for novel processes. Oleaginous yeasts represent a versatile tool to produce biobased chemicals and intermediates. They are flexible microbial factories able to grow on different side-stream carbon sources such as those deriving from agri-food wastes, and this characteristic makes them excellent candidates for integrated biorefinery processes through the production of microbial lipids, known as single cell oils (SCOs), for different applications. This review aims to present an extensive overview of research progress on the production and use of oleaginous yeasts and present discussions on the current bottlenecks and perspectives of their exploitation in different sectors, such as foods, biofuels and fine chemicals.

Functional characterization and overexpression of Δ12-desaturase in the oleaginous yeast Rhodotorula toruloides for production of linoleic acid-rich lipids

Linoleic acid (LA) has garnered much attention due to its potential applications in the oleochemical and nutraceutical industries. The oleaginous yeast Rhodotorula toruloides has outstanding lipogenecity, and is considered a potential alternative to the current plant-based platforms for LA production. Δ12-fatty acid desaturases (Δ12-Fads) are involved in LA synthesis in various fungi and yeasts, but their functions in R. toruloides remain poorly understood. To achieve the production of LA-rich lipids in R. toruloides, we investigated the function of the native Δ12-FAD (RtFAD2). First, the overexpression of RtFAD2 and its co-overexpression with RtFAD1 (encoding R. toruloides Δ9-Fad) and their effects on LA production in R. toruloides were investigated. The function of RtFad2 was confirmed by heterologous expression in Saccharomyces cerevisiae. Overexpression of RtFAD2 significantly elevated the LA contents and titers in the wild-type strain R. toruloides DMKU3-TK16 (TK16) and in a thermotolerant derivative of TK16 (L1-1). Additionally, overexpression of RtFAD2 in R. toruloides strains also increased the lipid titer and content. Overexpression of RtFAD1 was down-regulated in the RtFAD1 and RtFAD2 co-overexpressing strains, suggesting that the elevated LA content may function as a key regulator of RtFAD1 expression to control C18 fatty-acid synthesis in R. toruloides. We characterized the function of RtFAD2 and showed that its overexpression in R. toruloides increased the lipid and LA production. These findings may assist in the rational design of metabolic engineering related to LA or polyunsaturated fatty acid production in R. toruloides.

Hydrolytic secretome engineering in Yarrowia lipolytica for consolidated bioprocessing on polysaccharide resources: review on starch, cellulose, xylan, and inulin

Consolidated bioprocessing (CBP) featuring concomitant hydrolysis of renewable substrates and microbial conversion into value-added biomolecules is considered to bring substantial benefits to the overall process efficiency. The biggest challenge in developing an economically feasible CBP process is identification of bifunctional biocatalyst merging the ability to utilize the substrate and convert it to value-added product with high efficiency. Yarrowia lipolytica is known for its exceptional performance in hydrophobic substrates assimilation and storage. On the other hand, its capacity to grow on plant-derived biomass is strongly limited. Still, its high potential to simultaneously overproduce several secretory proteins makes Y. lipolytica a platform of choice for expanding its substrate range to complex polysaccharides by engineering its hydrolytic secretome. This review provides an overview of different genetic engineering strategies advancing development of Y. lipolytica strains able to grow on the following four complex polysaccharides: starch, cellulose, xylan, and inulin. Much attention has been paid to genome mining studies uncovering native potential of this species to assimilate untypical sugars, as in many cases it turns out that dormant pathways are present in Y. lipolytica's genome. In addition, the magnitude of the economic gain by CBP processing is here discussed and supported with adequate calculations based on simulated process models. KEY POINTS: • The mini-review updates the knowledge on polysaccharide-utilizing Yarrowia lipolytica. • Insight into molecular bases founding new biochemical qualities is provided. • Model industrial processes were simulated and the associated costs were calculated.

Valorization of low-cost, carbon-rich substrates by edible ascomycetes and basidiomycetes grown on liquid cultures

Three ascomycetes (Morchella vulgaris AMRL 36, M. elata AMRL 63, Tuber aestivum AMRL 364) and four basidiomycetes strains (Lentinula edodes AMRL 124 and 126, Agaricus bisporus AMRL 208 and 209) were screened for their ability to grow on liquid static flask cultures of glucose, glycerol, molasses and waste flour-rich hydrolysates with C/N ratio of 20 and produce biomass, exopolysaccharides and lipids. The profile of lipid fatty acids was also assessed. Selected strains were furthermore cultivated in C/N = 50. Results showed that substrate consumption, biomass formation and secondary metabolites production were strain, substrate and C/N ratio dependent. The maximum biomass (X), lipid (L) and exopolysaccharides (EPS) values noted were Xmax = 25.2 g/L (C/N = 20; molasses) and Lmax = 6.51 g/L (C/N = 50; rice cereal hydrolysates) by T. aestivum strain AMRL 364 and EPSmax = 2.41 g/L by M. elata strain AMRL 63 (C/N = 50; molasses), respectively. When C/N ratio of 50 was applied, biomass, lipid production and substrate consumption seem to be negatively affected in most of the trials. The adaptation and capability of the mushroom strains to be cultivated on substrates based on agro-industrial waste streams and infant food of expired shelf date offers the opportunity to set a circular oriented bioprocess.

Mixed glycerol and orange peel-based substrate for fed-batch microbial biodiesel production

The aqueous extraction of orange peel waste (OPW), the byproduct of the juice extraction process generated annually in massive amounts (21 Mton), yields a carbohydrate-rich liquid fraction, termed orange peel extract (OPE). Several studies highlight that the combination of glycerol, a biodiesel byproduct, with carbohydrate mixtures might boost microbial lipid production. This study performed first a shaken flask screening of 15 oleaginous yeast strains based on their growth and lipid-producing abilities on OPE- and glycerol-based media. This screening enabled the selection of R. toruloides NRRL 1091 for the assessment of the process transfer in a stirred tank reactor (STR). This assessment relied, in particular, on either single- and double-stage feeding fed-batch (SSF-FB and DSF-FB, respectively) processes where OPE served as the primary medium and nitrogen-containing glycerol-OPE mixtures as the feeding one. The continuous supply mode at low dilution rates (0.02 and 0.01 h-1 for SSF-FB and DSF-FB, respectively) starting from the end of the exponential growth of the initial batch phase enabled the temporal extension of biomass and lipid production. The SSF-FB and DSF-FB processes attained high biomass and lipid volumetric productions (LVP) and ensured significant lipid accumulation on a dry cell basis (YL/X). The SSF-FB process led to LVP of 20.6 g L-1 after 104 h with volumetric productivity (r L) of 0.20 g L-1 h-1 and YL/X of 0.80; the DSF-FB process yielded LVP, r L and YL/X values equal to 15.92 g L-1, 0.11 g L-1 h-1 and 0.65, respectively. The fatty acid profiles of lipids from both fed-batch processes were not significantly different and resembled that of Jatropha oil, a vastly used feedstock for biodiesel production. These results suggest that OPE constitutes an excellent basis for the fed-batch production of R. toruloides lipids, and this process might afford a further option in OPW-based biorefinery.

Optimization of Yarrowia lipolytica-based consolidated biocatalyst through synthetic biology approach: transcription units and signal peptides shuffling

Nowadays considerable effort is being pursued towards development of consolidated microbial biocatalysts that will be able to utilize complex, non-pretreated substrates and produce valuable compounds. In such engineered microbes, synthesis of extracellular hydrolases may be fine-tuned by different approaches, like strength of promoter, type of secretory tag, and gene copy number. In this study, we investigated if organization of a multi-element expression cassette impacts the resultant Yarrowia lipolytica transformants' phenotype, presuming that different variants of the cassette are composed of the same regulatory elements and encode the same mature proteins. To this end, Y. lipolytica cells were transformed with expression cassettes bearing a pair of genes encoding exactly the same mature amylases, but fused to four different signal peptides (SP), and located interchangeably in either first or second position of a synthetic DNA construction. The resultant strains were tested for growth on raw and pretreated complex substrates of different plant origin for comprehensive examination of the strains' acquired characteristics. Optimized strain was tested in batch bioreactor cultivations for growth and lipids accumulation. Based on the conducted research, we concluded that the positional order of transcription units (TU) and the type of exploited SP affect final characteristics of the resultant consolidated biocatalyst strains, and thus could be considered as additional factors to be evaluated upon consolidated biocatalysts optimization. KEY POINTS: • Y. lipolytica growing on raw starch was constructed and tested on different substrates. • Impact of expression cassette design and SP on biocatalysts' phenotype was evidenced. • Consolidated biocatalyst process for lipids production from starch was conducted.

Production of Raw Starch-Digesting Amylolytic Preparation in Yarrowia lipolytica and Its Application in Biotechnological Synthesis of Lactic Acid and Ethanol

Sustainable economy drives increasing demand for raw biomass-decomposing enzymes. Microbial expression platforms exploited as cellular factories of such biocatalysts meet requirements of large-volume production. Previously, we developed Yarrowia lipolytica recombinant strains able to grow on raw starch of different plant origin. In the present study, we used the most efficient amylolytic strain as a microbial cell factory of raw-starch-digesting (RSD) amylolytic preparation composed of two enzymes. The RSD-preparation was produced in fed-batch bioreactor cultures. Concentrated and partly purified preparation was then tested in simultaneous saccharification and fermentation (SSF) processes with thermotolerant Kluyveromyces marxianus for ethanol production and Lactobacillus plantarum for production of lactic acid. These processes were conducted as a proof-of-concept that application of the novel RSD-preparation supports sufficient starch hydrolysis enabling microbial growth and production of targeted molecules, as the selected strains were confirmed to lack amylolytic activity. Doses of the preparation and thermal conditions were individually adjusted for the two processes. Additionally, ethanol production was tested under different aeration strategies; and lactic acid production process was tested in thermally pre-treated substrate, as well. Conducted studies demonstrated that the novel RSD-preparation provides satisfactory starch hydrolyzing activity for ethanol and lactic acid production from starch by non-amylolytic microorganisms.

Orange peel waste-based liquid medium for biodiesel production by oleaginous yeasts

Orange peel waste (OPW), the primary byproduct of the juice extraction process, is annually generated in massive amounts (21 Mton), and its aqueous extraction in biorefining operations yields a liquid fraction, referred to as orange peel extract (OPE). Although OPE contains significant amounts of easily assimilable carbohydrates, such as fructose, glucose, and sucrose, no investigations have been conducted yet to assess its possible use in biodiesel production by oleaginous yeasts. Consequently, the objective of the present study was to assess whether OPE might act as the basis of a liquid medium for microbial lipid production. A screening conducted with 18 strains of oleaginous yeasts in shaken flask on the OPE-based medium showed that Rhodosporidium toruloides NRRL 1091 and Cryptococcus laurentii UCD 68-201 gave the best results in terms of lipid production (5.8 and 4.5 g L^-1, respectively) and accumulation (77 and 47% on a dry matter basis, respectively). The subsequent scale transfer of the process to a 3-L STR operated in batch mode halved the time required to reach the lipid peak with the ensuing increase in volumetric productivities in R. toruloides NRRL 1091 (3646 mg L^-1 day^-1) and C. laurentii UCD 68-201 (2970.7 mg L^-1 day^-1). The biodiesel yields from the lipids of the former and the latter strain were 36.9 and 31.9%, respectively. Based on multivariate analysis of fatty acid methyl ester compositions, the lipids from the former and the latter strain were highly resembling those of Jatropha and palm oils, two commonly used feedstocks for biodiesel manufacturing.

Optimization of Protease and Amylase Production by Rhizopus oryzae Cultivated on Bread Waste Using Solid-State Fermentation

This research was carried for the coproduction of two industrial enzymes: α-amylase and protease via SSF by Rhizopus oryzae on humidified bread waste. Fermentation time, inoculum size, initial moisture content, salt solutions, and the thickness of the substrate were investigated one by one. Fungus culture was carried out in sterile aluminum trays, and pH was adjusted to 5.5. The main results showed that the highest levels of enzyme production were obtained at 120 h, 65% relative humidity, height media of 1 cm, 105 spore/g, and M-9 solution (g/L): NaH2PO4, 12.8; KH2PO4, 3; NaCl, 0.5; NH4Cl, 1; MgSO4 7H2O, 0.5; CaCl2 2H2O, 0.01. α-Amylase (100 U/g) and protease (2400 U/g) produced by SSF from Rhizopus oryzae (CH4) on BW as substrate are of great interest in industries and could be valorized as enhancers of the bread making process.