Optimization of gibberellic acid production by immobilized Gibberella fujikuroi mycelium in fluidized bioreactors

An orthogonal experimental design L9 (3(4)) was used to investigate effects of temperature, pH, C:N ratio (glucose-C, NH4Cl-N) and concentrations of rice flour on production of gibberellic acid by Gibberella fujikuroi in 3.5 l fluidized bioreactors. The gibberellic acid production in a fluidized bioreactor could reach 3.90 g l(-1), more than 3-times greater than previously reported for submerged and solid fermentations. pH, rice flour concentration and C:N ratio were the factors that most influenced the production of gibberellic acid; pH being the most important. The response surface of gibberellic acid production to changes in pH and C:N ratio or rice flour concentration indicated that greatest production was found with a C:N ratio of 36.8 and pH 5 while the optimum concentration for rice flour was 2 g l(-1) and production increased with increased pH. The effect of temperature on the production of gibberellic acid was also significant and greatest production was at 30 degrees C.     

Continuous penicillin production by Penicillium chrysogenum immobilized in calcium alginate beads

Summary A high penicillin-producing Penicillium chrysogenum strain immobilized in calcium alginate beads was used for continuous penicillin fermentation in a bubble column and in a conical bubble fermentor. The fermentation was limited by the growth rate, dilution rates and the stability of the alginate beads. The immobilized cells lost their ability to produce penicillin in the bubble column after 48 h from beginning of the continuous fermentation. In the conical bubble fermentor the immobilized cells remained active for more than 7 days. This bioreactor ensured a good distribution of nutrients and oxygen as well as a higher mechanical stability of the alginate beads.     

Morphological mutants of Gibberella fujikuroi for enhanced production of gibberellic acid

AIMS: To examine the production of gibberellic acid by selected morphological mutants of Gibberella fujikuroi in liquid cultures. METHODS AND RESULTS: Mutants of G. fujikuroi having different morphological characteristics were selected after UV irradiation. The production of gibberellic acid by mutants that had different hyphal lengths was examined in shake flasks in media with different concentrations of nutrients as well as different volumes of the medium. Fed-batch fermenter study was performed to evaluate the mutant Mor-25 for growth and production of gibberellic acid. The broth was analysed by high performance liquid chromatography for fusaric acid, the common mycotoxin produced by strains of Fusarium. A variety of morphological mutants having different mycelial and soluble pigmentation as well as colony morphologies were generated from G. fujikuroi upon exposure to UV radiation. A nonpigmented mutant (Car-1) was selected as intermediate parent and later, mutants Mor-1 and Mor-25 were selected based on their distinct morphology. The colonies on regeneration agar plates were small, compact and dry. In liquid medium, mutant Mor-25 grew in a micro-pelleted form and the mycelium had short, highly branched hyphae, curly at tips with thick, swollen cells. Mutant Mor-25 grew rapidly in a low-cost medium containing defatted groundnut flour, sucrose and salts. In media with higher nutrient concentrations as well as larger volumes, it produced twofold more gibberellic acid than the parent. Fusaric acid, the common mycotoxin, was absent in the fermentation broth of mutant Mor-25. The mutants have been deposited in National Collection of Industrial Microorganisms (NCIM), National Chemical Laboratory, Pune, India under following culture collection numbers (Car-1, NCIM 1323; Mor-1, NCIM 1322; and Mor-25, NCIM 1321). CONCLUSIONS: Growth of unpigmented, morphological mutants of G. fujikuroi that led to lower viscosity in fermentation broth resulted in increased production of gibberellic acid. SIGNIFICANCE AND IMPACT OF THE STUDY: The use of morphological mutants that have lower viscosity in liquid cultures for gibberellic acid production is not reported earlier. Similar mutants can be useful for other types of fungal fermentations also.     

Effect of silicone oil on gibberellic acid production by Gibberella fujikuroi and Aspergillus niger

The effect of silicone oil on gibberellic acid production was investigated using Gibberella fujikuroi and Aspergillus niger fungi. Silicone oil was used as an oxygen vector in the gibberellic acid production process. When silicone oil was used, the concentration of gibberellic acid increased 4.6 and 6.7 times with respect to the control run having A. niger and G. fujikuroi microorganisms, respectively. The text was submitted by the authors in English.     

Kinetics of Gibberella fujikuroi growth and gibberellic acid production by solid-state fermentation in a packed-bed column bioreactor

In this work the growth of Gibberella fujikuroi and gibberellic acid (GA3) production were studied using coffee husk and cassava bagasse as substrates in a packed-bed column bioreactor connected to a gas chromatograph for exit gas analysis. With the respirometric data, a logarithmic correlation between accumulated CO2 and biomass production was determined, and the kinetics of the fungal growth was compared for estimated and experimental data. The solid medium consisted of coffee husk (pretreated with alkali solution), mixed with cassava bagasse (7:3 dry weight basis), with a substrate initial pH of 5.2 and moisture of 77%. Cultivation was carried out in glass columns, which were packed with preinoculated substrate and with forced aeration of 0.24 L of air/[h (g of substrate)] for the first 3 days, and 0.72 L of air/[h (g of substrate)] for the remaining period. The maximum specific growth rate (microm) obtained was 0.052 h(-1) (between 24 and 48 h of fermentation). A production of 0.925 g of GA3/kg of substrate was achieved after 6 days of fermentation.     

Effect of silicone oil on the gibberellic acid production by Gibberella fujikuroi and Aspergillus niger

The effect of silicone oil on gibberellic acid production was investigated using Gibberella fujikuroi and Aspergillus niger fungi. Silicone oil was used as an oxygen vector in the gibberellic acid production process. When silicone oil was used, gibberellic acid concentration increased with respect to the control run having A. niger and G. fujikuroi microorganisms 4.6 and 6.7 times, respectively.     

Selective production of bikaverin in a fluidized bioreactor with immobilized Gibberella fujikuroi

The best culture medium composition for the production of bikaverin by Gibberella fujikuroi in shake-flasks, i.e. 100 g glucose l^–1; 1 g NH₄Cl l^–1; 2 g rice flour l^–1; 5 g KH₂PO₄ l^–1 and 2.5 g MgSO₄ l^–1, was obtained through a fractional factorial design and then scaled-up to a fluidized bioreactor. The effects of carbon and nitrogen concentrations, inoculum size, aeration, flow rate and bead sizes on batch bikaverin production using immobilized G. fujikuroi in a fluidized bioreactor were determined by an orthogonal experimental design. Concentrations of up to 6.83 g bikaverin l^–1 were obtained when the medium contained 100 g glucose l^–1 and 1 g NH₄Cl l^–1 with an inoculum ratio of 10% v/v, an aeration rate of 3 volumes of air per volume of medium min^–1, and a bead size of 3 mm. Based on dry weight, the bikaverin production was 30–100 times larger than found in submerged culture and approximately three times larger than reported for solid substrate fermentation.     

Semicontinuous penicillin production by two Penicillium chrysogenum strains immobilized in calcium alginate beads

Summary The growth rates of immobilized Penicillium chrysogenum strains are important in their application to semicontinuous penicillin production. Immobilized P. chrysogenum strains produced about 10–15% less biomass but about 1–2 times more penicillin than free suspended mycelia.In a chemically defined medium an industrial P. chrysogenum strain, S₁, produced about 10–12 times more penicillin than strain ATCC 12690. In a complex medium the immobilized P. chrysogenum S₁ produced about 12% penicillin more than in shaken cultures. In bubble column fermentations, penicillin production was 163% higher in the complex medium than in the chemically defined medium.     

Effect of compactin on the incorporation of mevalonolactone into gibberellic acid by Gibberella fujikuroi

In Gibberella fujikuroi, strain GF-1a, the effect of the sodium salt of compactin on the incorporation of both radiolabelled acetate and mevalonate into gibberellic acid has been investigated. In each case, a concentration of 40 mg/1. caused a significant reduction in the incorporation.     

Continuous ethanol production by immobilized yeast reactor

Summary Saccharomyces cerevisiae yeast immobilized in calcium alginate gel beads was employed in packed-bed column reactors for continuous ethanol production from glucose or cane molasses, and for beer fermentation from barley malt wort. With properly balanced nutrient content or periodical regeneration of cells by nutrient addition and aeration, ethanol production could be maintained for several months. About 7 percent (w/v) ethanol content could be easily maintained with cane molasses diluted to about 17.5 percent (w/v) of total reducing sugars at about 4 to 5 h residence time. Beer of up to 4.5 percent (wv) of ethanol could be produced from barley wort at about 2 h residence time without any addition of nutrients.     

Immobilized growing cells of Gibberella fujikuroi P-3 for production of gibberellic acid and pigment in batch and semi-continuous cultures

Summary The performance of immobilized growing cells of Gibberella fujikuroi P-3 was affected by the immobilization agent used, nature and age of cells, mycelial cell density, size of beads and inclusion of linseed oil. The beads, prepared by using standardized procedures, could be used for 8 cycles without affecting productivity in semicontinuous culture. The rate of production of gibberellic acid was 0.58–0.66 mg/l/h. An inverted conical fluidized bioreactor, based on the design employed in continuous plant cell culture, was adopted. This bioreactor offers many advantages. The pigment produced by the fungus is not similar to bikaverin, norbikaverin and O-dimethylanhydrofusarubin, the known polyketides.     

Continuous ethanol production by immobilized yeast in a fluidized reactor

Summary In order to minimize the adverse effect of CO₂ gas in a packed bed immobilized yeast reactor, a fluidized bed reactor was used for the continuous production of ethanol from glucose. Immobilized yeast was prepared by entrapping whole cells of Saccharomyces cerevisiae within a Caalginate matrix. It was found that the efficiency of the ethanol production in a fluidized bed reactor was 100% better than that for a packed bed reactor system. The alcohol productivity obtained was 21 g/l/hr in a fluidized bed reactor at 94% of conversion level.     

Protease production by immobilized growing cells of Serratia marcescens and Myxococcus xanthus in calcium alginate gel beads

Summary Serratia marcescens and Myxococcus xanthus cells were immobilized in calcium alginate gel beads. Immobilization under various conditions had no effect on the extracellular proteolytic activity of S. marcescens cells. Protease production seemed rather to depend on the free cells in the medium. However, the stability over time of enzyme production was enhanced, as immobilization increased protease production half-life from 5 to 12 days. On the other hand, Myxococcus xanthus produced proteases inside the gel beads which could diffuse into the medium. The proteolytic activity increased as a function of the initial cell content of the beads and of the bead inoculum. Compared to free cells, immobilized cells of Myxococcus xanthus could produce 8 times more proteolytic activity, with a very low free-cell concentration in the medium.     

Capture of volatile metabolites for tracking the evolution of gibberellic acid in a solid-state culture of Gibberella fujikuroi

The evolution of volatile compounds produced during solid substrate cultivation (SSC) of Gibberella fujikuroi on wheat bran was tracked looking for volatile metabolites related with GA₃ production. Ethyl acetate and isoamyl acetate gave identical profiles and sharp increases that abated as the production of GA₃ began, while ent-kaurene displayed a profile matching that of the development of GA₃. ent-Kaurene is a precursor in the synthesis of gibberellins and was the most abundant compound found.     

Continuous production of lacticin 3147 and nisin using cells immobilized in calcium alginate

Bacteriocinogenic strains, Lactococcus lactis subsp. lactis DPC 3147 and L. lactis DPC 496, producing lacticin 3147 and nisin, respectively, were immobilized in double-layered calcium alginate beads. These beads were inoculated into MRS broth at a ratio of 1:4 and continuously fermented for 180 h. Free cells were used to compare the effect of immobilization on bacteriocin production. After equilibrium was reached, a flow rate of 580 ml h(-1) was used in the immobilized cell (IC), and 240 ml h(-1) in free-cell (FC) bioreactors. Outgrowth from beads was observed after 18 h. Bacteriocin production peaked at 5120 AU ml(-1) in both IC and FC bioreactors. However, FC production declined after 80 h to 160 AU ml(-1) at the end of the fermentation. Results of this study indicate that immobilization offers the possibility of a more stable and long-term means of producing lacticin 3147 in laboratory media than with free cells.     

Erythromycin production by Streptomyces erythreus entrapped in calcium alginate beads

Summary Mycelia of Streptomyces erythreus were immobilized in calcium alginate beads and employed for production of erythromycin. Compared to conventional and washed mycelial fermentation, the average specific productivity of immobilised mycelia was superior.     

Culture parameters affecting xylitol production by Debaryomyces hansenii immobilized in alginate beads

Yeast immobilization offers operational advantages such as high cell concentration, and some drawbacks related to cell leaking and restricted mass transfer inside particles. The influence of bead size, chitosan, bead charge, volume of liquid media, and the use of corncob hydrolyzates and vinasses as culture medium were analyzed on xylitol production by Debaryomyces hansenii immobilized in alginate beads. The results showed a profuse growth of free cells, accounting 75–95% of total biomass, but electron micrographs revealed the generation of a dense biofilm with hyphal morphology at the bead surface and a very low intraparticular growth. Xylitol production was not affected by the size of particle; however chitosan had a negative effect. The use of corn cob as carbon source and twofold diluted vinasses as economic nutrients incremented xylitol concentration to 13.7 g L^?1 (Y_P/S = 0.56 g g^?1; Q_P = 0.29 g L^?1 h^?1). The best conditions corresponded to high bead charges and intermediate liquid volumes (44 g Na-alginate and 110 mL liquid medium). These results showed the feasibility of employing these cheap substrates, reflected the importance of the microaerobical conditions, and pointed to the favorable effect of cell immobilization on the metabolism of xylitol production.     

Production of glucoamylase using Aspergillus phoenicus immobilized in calcium alginate beads

Summary As a means of better exploiting the growth-dissociated nature of glucoamylase synthesis, a production process in which the growth phase was separated from the enzyme synthesis phase has been developed. Immobilized mycelia arising from a 6-day-old culture of conidia immobilized in calcium alginate beads could be subsequently used repeatedly to produce glucoamylase in a second step using a Dextran T-10 medium. Glucoamylase production was sustained over five sequential batches in a 19-day period and immobilized mycelia remained confined to the subsurface of the beads. Offprint requests to: C. Kuek     

Production of gibberellins and bikaverin by cells of Gibberella fujikuroi immobilized in carrageenan

The production of gibberellins and bikaverin by immobilized and free cells of Gibberella fujikuroi strains was followed. Both types of cells, free and immobilized, produced similar titers of the secondary metabolites during the normal growth cycle. The kinetics of nutrient use and product formation by the immobilized cells lagged behind that of the free cells and this was assumed to be the result of diffusional limitations imposed on the immobilized cells. A noticeable difference was that in the immobilized cells, all of the bikaverin was excreted into the medium for both strains of G. fujikuroi tested but in the free cell fermentation 44% was excreted for strain ACC 917 and only 10% for strain GF1a. Gibberellin and bikaverin could be produced in a semi-continuous fashion with both free and immobilized cells for a period of 16 d in a resuspension medium containing 0.12 mM or 0.60 mM ammonium chloride. No definite advantage, on a productivity basis, for using immobilized cells over free cells could be seen.     

Enhanced production of bioethanol and ultrastructural characteristics of reused Saccharomyces cerevisiae immobilized calcium alginate beads

Yeast immobilized on alginate beads produced a higher ethanol yield more rapidly than did free yeast cells under the same batch-fermentation conditions. The optimal fermentation conditions were 30 °C, pH 5.0, and 10% initial glucose concentration with 2% sodium alginate beads. The fermentation time using reused alginate beads was 10-14 h, whereas fresh beads took 24 h, and free cells took 36 h. All bead samples resulted in nearly a 100% ethanol yield, whereas the free cells resulted in an 88% yield. Transmission electron microscopy (TEM) showed that the shortened time and higher yield with the reused beads was due to a higher yeast population per bead as well as a higher porosity. The ultrastructure of calcium alginate beads and the alginate matrix structure known as the “egg-box” model were observed using TEM.