Immobilized salt-tolerant yeasts: application of a new polyethylene-oxide support in a continuous stirred-tank reactor for flavour production

Immobilization of salt-tolerant yeasts considerably decreases the total time required for the flavour development in soy-sauce processes. For immobilization of cells, alginate gel is mostly used as support material. However, alginate is not very suitable for use in soy-sauce processes because alginate is sensitive to abrasion and chemically unstable towards the high salt content of the soy-sauce medium. In contrast, a newly developed polyethylene-oxide gel seems to be more suitable, but this gel has not been used so far for flavour production in a bioreactor with a high salt content. Therefore, this gel was applied with immobilized salt-tolerant yeasts in a continuous stirred-tank reactor, containing more than 12.5% (w/v) salt. In this reactor, the polyethylene-oxide gel particles did not show any abrasion for several days, while alginate gel beads were already destroyed within 1 day. In addition, the polyethylene-oxide gel particles with immobilized salt-tolerant yeasts Candida versatilis and Zygosaccharomyces rouxii showed a good flavour production. From this work, it was concluded that the application of polyethylene-oxide gel in long-term soy-sauce processes is attractive in the case the sticking together of polyethylene-oxide gel particles can be controlled.     

Developing microbial biofilm as a robust biocatalyst and its challenges

Biocatalysts, such as bacteria, yeast, fungi and the enzymes they produce, have been used for many industrial applications since they function as effective and environmentally friendly tools. Whole cells have also been used in many sophisticated bioprocesses since a number of sequential reactions can be catalyzed within the cells. However, the use of whole cells in suspension in batch, fed-batch and continuous processes has some limitations. For instance, the cultures are non-reusable, they are sometimes sensitive to the toxicity of substrates or products, there can be issues with short-term stability, and each of these issues can impede biocatalyst regeneration, perturbing the downstream process and causing complexity in running large scale continuous culture. Recently, biofilms have emerged as a new generation of biocatalysts to solve these limitations in the production of many bio-based materials, including chemicals, antibiotics, enzymes, bioethanol, biohydrogen, and electricity production via microbial fuel cells. The establishment of industrial processes using biofilms has the potential for high benefit in terms of low-cost cell immobilization without the necessity of added polymers or chemicals. Many small-scale biofilm reactors have been developed for the production of value-added products, and it may be challenging to establish it on an industrial scale.     

Immobilized plant cell reactors

The use of plant cells for the production of biochemicals represents a new area of biotechnological exploration. The techniques envisioned for industrial processes are related to those developed for microorganisms and a strong emphasis should be placed on immobilized cell systems. This review examines the spectrum of products that are synthesized by higher plants and the immobilization techniques that are suited to entrap plant cells from suspension culture. Different reactor configurations are described. Both packed-bed reactors with alginate-entrapped cells and hollow-fibre cartridges with sequestered cells have utility for the continuous production of biochemicals.     

Mass transfer effects in fermentations using immobilized whole cells

The immobilization of whole cells for fermentation processes has many potential advantages over fermentation with free cells, including higher cell concentrations, higher productivites and a higher level of operational stability. Most of the research reported in the literature has been directed towards demonstrating the feasibility of using these systems for various fermentations. The ultimate goal of research in this area is to bring the understanding of immobilized whole cells to the level of heterogeneous catalysis. Immobilized whole cell systems are examined from a mass transfer perspective. Evidence for external and internal mass transfer limitations is presented. Procedures for quantifying these effects in terms of effectiveness factors and determining the reaction kinetics in their presence are reviewed. Development of the reactor design equations and the reactor performance results for fermentations with immobilized cells are also discussed.     

Urocanic acid production using whole cells immobilized in a hollow fiber reactor

The feasibility of using hollow fiber membrane dialyzers (C-DAK) for immobilization of microbial whole cells was investigated. The cells are located on the shell side of the dialyzer, while substrates and products are free to diffuse across the hollow fiber membranes. The biochemical reaction studied was the conversion of L -histidine to urocanic acid and catalyzed by L -histidine ammonia-lyase. C-DAK dialyzers containing a heat-treated suspension of Pseudomonas fluorescens ATCC 11299b (with L -histidine ammonia–lyase activity) were incorporated into constant volume recycle reactor systems for continuous product formation. A simple model successfully correlated the data and predicted performance. It was found that the reaction was not likely to be diffusion limited, and such a cell immobilization scheme is convenient and workable for continuous production of biochemicals.     

Column flow reactor using acetohydroxyacid synthase I from Escherichia coli as catalyst in continuous synthesis of R-phenylacetyl carbinol

We tested the possibility of utilizing acetohydroxyacid synthase I (AHAS I) from Escherichia coli in a continuous flow reactor for production of R-phenylacetyl carbinol (R-PAC). We constructed a fusion of the large, catalytic subunit of AHAS I with a cellulose binding domain (CBD). This allowed purification of the enzyme and its immobilization on cellulose in a single step. After immobilization, AHAS I is fully active and can be used as a catalyst in an R-PAC production unit, operating either in batch or continuous mode. We propose a simplified mechanistic model that can predict the product output of the AHAS I-catalyzed reaction. This model should be useful for optimization and scaling up of a R-PAC production unit, as demonstrated by a column flow reactor.     

Biofilm reactors for industrial bioconversion processes: employing potential of enhanced reaction rates

This article describes the use of biofilm reactors for the production of various chemicals by fermentation and wastewater treatment. Biofilm formation is a natural process where microbial cells attach to the support (adsorbent) or form flocs/aggregates (also called granules) without use of chemicals and form thick layers of cells known as "biofilms." As a result of biofilm formation, cell densities in the reactor increase and cell concentrations as high as 74 gL^-1 can be achieved. The reactor configurations can be as simple as a batch reactor, continuous stirred tank reactor (CSTR), packed bed reactor (PBR), fluidized bed reactor (FBR), airlift reactor (ALR), upflow anaerobic sludge blanket (UASB) reactor, or any other suitable configuration. In UASB granular biofilm particles are used. This article demonstrates that reactor productivities in these reactors have been superior to any other reactor types. This article describes production of ethanol, butanol, lactic acid, acetic acid/vinegar, succinic acid, and fumaric acid in addition to wastewater treatment in the biofilm reactors. As the title suggests, biofilm reactors have high potential to be employed in biotechnology/bioconversion industry for viable economic reasons. In this article, various reactor types have been compared for the above bioconversion processes.     

Increased phenotypic stability and ethanol tolerance of recombinant Escherichia coli KO11 when immobilized in continuous fluidized bed culture

The recombinant Escherichia coli B strain KO11, containing chromosomally-integrated genes for ethanol production, was developed for use in lignocellulose-to-ethanol bioconversion processes but suffers from instability in continuous culture and a low ethanol tolerance compared to yeast. Here we report the ability cell immobilization to improve its phenotypic stability and ethanol tolerance during continuous culture on a 50 g/L xylose feed. Experiments conducted in a vertical tubular fermentor operated as a liquid-fluidized bed with the cells immobilized on porous glass microspheres were compared to control experiments in the same reactor operated as a chemostat without the support particles. Without cell immobilization the ethanol yield fell sharply following start-up, declining to 60% of theoretical after only 8-9 days of continuous fermentation. While immobilizing the cells did not prevent this decline, it delayed its onset and slowed its rate. With immobilization, a stable high ethanol yield (>85%) was maintained for at least 10 days, thereafter declining slowly, but remaining above 70% even after up to 40 days of fermentation. The ethanol tolerance of E. coli KO11 cells was substantially increased by immobilization on the glass microspheres. In ethanol tolerance tests, immobilized cells released from the microspheres had survival rates 2.3- to 15-fold higher than those of free cells isolated from the same broth. Immobilization is concluded to be an effective means of increasing ethanol tolerance in E. coli KO11. While immobilization was only partially effective in combating its phenotypic instability, further improvements can be expected following optimization of the immobilization conditions.     

Nitrilase immobilization and transposition from a micro-scale batch to a continuous process increase the nicotinic acid productivity

In recent years, many biocatalytic processes have been developed for the production of chemicals and pharmaceuticals. In this context, enzyme immobilization methods have attracted attention for their advantages, such as continuous production and increased stability. Here, enzyme immobilization methods and a collection of nitrilases from biodiversity for the conversion of 3-cyanopyridine to nicotinic acid were screened. Substrate conversion over 10 conversion cycles was monitored to optimize the process. The best immobilization conditions were found with cross-linking using glutaraldehyde to modify the PMMA beads. This method showed good activity over 10 cycles in a batch reactor at 30 and 40°C. Finally, production with a new thermostable nitrilase was examined in a continuous packed bed reactor, showing very high stability of the biocatalytic process at a flow rate of 0.12 ml min^–1 and a temperature of 50°C. The complete conversion of 3-cyanopyridine was obtained over 30 days of operation. Future steps will concern reactor scale-up to increase the production rate with reasonable pressure drops.     

Continuous production of L-tryptophan from indole and L-serine by immobilized Escherichia coli cells

Escherichia coli B 10, which has high activity of tryptophan synthetase, was grown in a 50-L batch culture in order to determine in which growth phase the cells have the highest specific tryptophan productivity. Accordingly, whole cells of the stationary phase were used for immobilization in polyacrylamide beads. After immobilization, these immobilized cells had 56% activity of tryptophan synthetase compared with that of free cells. First, the properties of immobilized cells were investigated. Next, discontinuous productions of L-tryptophan were carried out by using immobilized cells. In discontinuous production of L-tryptophan by the batch, the activity remaining of immobilized cells was 76-79% after 30 times batchwise use. In continuous production of L-tryptophan with a continuous stirred tank reactor (CSTR), the activity remaining of the immobilized cells was 80% after continuous use for 50 days. The maximum productivity of L-tryptophan in this CSTR system was 0.12 g tryptophan L(-1) h(-1).     

Immobilization of yeast cells on various supports for ethanol production

An immobilization technique has been developed for a packed bed fermenter which is being considered as one stage of a process for the production of fuel-grade ethanol from sugar solutions. Relatively inexpensive beech wood chips have been successfully used as the support material and relatively high cell loadings of 188 mg DW cells/g DW support have been achieved for a test system of Saccharomyces cerevisiae cultures.No washout of adsorbed cells occurs below a superficial liquid velocity of 8.9 × 10^-2 cm/s which can be increased to 9.7 × 10^-2 cm/s by including up to 1% Hercofloc solution in the reactor medium during the immobilization procedure. The immobilization procedure is practically unaffected by pH and temperature in the range 3.5 to 5.0 and 22 °C to 37 °C respectively.Typical ethanol productivity of 21.8g/l·hr has been obtained with wood-chip-adsorbed cells, which compares well with optimal values of 18 to 32g/l·hr obtained using free-suspension cultures in stirred-tank fermenters with cell recycle.     

Production of toluene cis-diol by immobilized pseudomonas putida UV4 cells in barium alginate beads

In the present study, we have investigated the biotransformation of toluene to its cis-dihydrodiol (cis-diol) with immobilized Pseudomonas putida UV4 cells using different conditions of immobilization with a view to improving its production. The choice of alginate and its concentration for the immobilization of the cells were found to be the most important factors affecting the production of toluene cis-diol. The concentration of minerals and oxygen in the reaction medium and the methodology of substrate addition were investigated and the optimal conditions were defined. Once the optimal conditions for biotransformations and entrapment were determined, a packed-bed and fluidized-bed reactor were evaluated for the biotransformation process. The results using air as the gas supply showed an increase in the total production from 0.15 mol cis-diol · g⁻¹ dry cell weight (dcw) in the packed-bed reactor to 0.28 mol cis-diol · g⁻¹ dcw in the fluidized-bed reactor. When pure oxygen was used in place of air in the fluidized-bed reactor, a dramatic increase in total production up to a maximum of 6.1 mol cis-diol · g⁻¹ dcw using a medium flow rate of 100 ml min⁻¹ was achieved. Under optimal conditions, a maximum rate of production of 86.9 mmol cis-diol g⁻¹ dcw h⁻¹ was achieved for 48 h. This was seven times higher than the rate previously reported in the literature and for a much longer period of time; consequently, the overall production observed was more than 75 times higher than the values reported in the literature.     

Continuous glutamate production using an immobilized whole-cell system

For the purpose of saving the energy and raw materials required in glutamate fermentation, an immobilized whole-cell system was prepared and its performance in a continuous reactor system was evaluated. Corynebacterium glutamicum (a mutant strain of ATCC 13058) whole cell was immobilized in K-carrageenan matrix and the gel structure was strengthened by treatment with a hardening agent. The effective diffusivities of carrageenan gel for glucose and oxygen were found to decrease significantly with an increase in carrageenan concentration, while the gel strength showed an increasing trend. Based on the physical and chemical properties of carrageenan gel, the immobilization method was improved and the operation of the continuous reactor system was partially optimized. In an air-stirred fermentor, the continuous production of glutamate was carried out. The effect of the dilution rate on glutamate production and operational stability were investigated. The performance of the continuous whole-cell reactor system was evaluated by measuring glutamate productivity for a period of 30 days; it was found to be far superior to the performance of conventional batch reactor systems using free cells.     

Physical property improvements of a pellicular biocatalyst

The thermal stability of an immobilization technique using a pellicular latex matrix was examined in a packed-bed column reactor. The stability was found to vary with liquid flow rate, the type of latex, temperature of operation, and the amount of yeast cells. Adjusting these parameters and introducing particulate inorganic fillers strengthened the latex matrix and improved the thermal stability. Optimization of this immobilization technique resulted in a procedure that allowed latex polymers to be mechanically stable at temperatures up to 50°C. The biological viability of this improved immobilization scheme was demonstrated through the production of L-aspartic acid by immobilized cells of E. coli.     

Effect of serum concentration on retroviral vector production from the amphotropic ψCRIP murine producer cells

The production of ethanol by Saccharomyces cerevisiae immobilized cells and its esterification with oleic acid, catalysed by a lipase from Rhizomucor miehei, was the biochemical process considered as model to illustrate the concept of extractive biocatalysis. The selection of the most suitable support for lipase immobilization was carried out. The best results for the ethanol/oleic acid esterification reaction were obtained with the lipase adsorbed on a polyamide type support, Accurel EP 700. The immobilization method was optimized in terms of immobilization pH, contact time and protein/support ratio. The better performances of the extractive fermentations of ethanol were obtained when entrapped k-carrageenan Saccharomyces cerevisiae cells and a lipase from Rhizomucor miehei, free or immobilized in Accurel EP 700, were used simultaneously. The observed reutilization capacity of the immobilized enzyme could be advantageous for its application in a continuous reactor.     

Enhanced bioconversion of colchicine to regiospecific 3-demethylated colchicine (3-DMC) by whole cell immobilization of recombinant E. coli harboring P450 BM-3 gene

Biotransformation of colchicine into regiospecific 3-demethylated colchicine (3-DMC) which is pharmacologically active and a potent anti-cancer drug, mediated by immobilization of recombinant microbial monooxygenases is a novel and promising strategy for its production. In the present study, recombinant Escherichia coli expressing P450 BM-3 was immobilized in calcium-alginate beads and its ability to catalyze colchicine into 3-DMC was investigated. Characteristics of immobilized system showed that optimum conditions for activity of microbial cells were not affected due to immobilization. The optimum pH and temperature for both free and immobilized cells were found to be 7.5 and 37.5 °C, respectively. Experimental variables under consideration such as Ca²⁺ concentration, alginate concentration, P450 BM-3 enzyme activity and colchicine concentration were optimized using response surface methodology. The immobilized cells exhibited a markedly improved thermal stability as compared to free cells. The yield of 3-DMC with immobilized microbial cells was found to be an average of 69%, with 82, 73 and 52% across three independent batches in succession as against bioconversion by free cells, which indicated improved operational stability and reusability of immobilized cells in batch processes. Additionally, a packed bed reactor has been proposed for the immobilized biocatalytic system for bioconversion of colchicine and other biochemicals.     

Protein engineering of Acidovorax facilis 72W nitrilase for bioprocess development

Hydroxycarboxylic acid monomers can be used to prepare industrially important polymers. Enzymatic production of such hydroxycarboxylic acids is often preferred to chemical production since the reactions are run at ambient temperature, do not require strongly acidic or basic reaction conditions, and produce the desired product with high selectivity at high conversion. However, native enzymes often do not perform desired reactions with the efficiency required for commercial applications. Protein engineering was used to significantly increase the specific activity of nitrilase from Acidovorax facilis 72W for the conversion of 3-hydroxyvaleronitrile to 3-hydroxyvaleric acid. Overexpression of engineered nitrilase enzymes in Escherichia coli, combined with immobilization of whole cells in alginate beads that can be recycled many times has facilitated the development of a commercially viable bioprocess for production of 3-hydroxyvaleric acid.     

Immobilization of an amino acid racemase for application in crystallization‐based chiral resolutions of asparagine monohydrate

Integration of racemization and a resolution process is an attractive way to overcome yield limitations in the production of pure chiral molecules. Preferential crystallization and other crystallization‐based techniques usually produce low enantiomeric excess in solution, which is a constraint for coupling with racemization. We developed an enzymatic fixed bed reactor that can potentially overcome these unfavorable conditions and improve the overall yield of preferential crystallization. Enzyme immobilization strategies were investigated on covalent‐binding supports. The amino acid racemase immobilized in Purolite ECR 8309F with a load of 35 mg‐enzyme/g‐support showed highest specific activity (approx. 500 U/g‐support) and no loss in activity in reusability tests. Effects of substrate inhibition observed for the free enzyme were overcome after immobilization. A packed bed reactor with the immobilized racemase showed good performance in steady state operation processing low enantiomeric excess inlet. Kinetic parameters from batch reactor experiments can be successfully used for prediction of packed bed reactor performance. Full conversions could be achieved for residence times above 1.1 min. The results suggest the potential of the prepared racemase reactor to be combined with preferential crystallization to improve resolution of asparagine enantiomers.     

Culture and bioconversion use of plasmid-harboring strain of immobilized E. coli

Summary Growing Escherichia coli BZ18/pTG 201 cells were immobilized in Kappa-carrageenan gel beads. The bacterial growth after immobilization was studied by cellular counting and by morphological observations with electron microscopy. Kinetic studies of the Catechol 2–3 dioxygenase carried by the plasmid pTG 201 were performed with a packed-bed reactor to show the potential of such a system. High cell densities 1.7×10¹¹ cells/ml) were observed in the cavities of the gel. Due to the difference between the cell density in suspension (8x10⁸ cells/ml) and that within the gel cavities, a reduction of the reactor size and investment cost for processes can be predicted.     

Ceramic honeycomb as support for covalent immobilization of laccase from Trametes versicolor and transformation of nuclear fast red

The covalent immobilization of laccase on an inorganic ceramic support was investigated. The intention was to find a system of enzyme and reactor for a universal immobilization procedure. Laccase from Trametes versicolor as model enzyme was chosen. The special honeycomb structure of the monolith can be applied for intensive mixing of the reaction compounds. An appropriate reactor with ceramic material was constructed allowing different setup for enzyme immobilization and its application. To test the success of the immobilization, 2,2-azino-bis (3-ethylbenzothiazoline-6-sulfonic acid) was used. The immobilized laccase was found to be stable over a time period of over 3 months. As an example for possible application for treatment of wastewater containing dyes, the conversion of nuclear fast red as model substrate was tested.