Response surface methodology for optimising the culture conditions for eicosapentaenoic acid production by marine bacteria

Polyunsaturated fatty acids (PUFAs), especially eicosapentaenoic acid (EPA), are increasingly attracting scientific attention owing to their significant health-promoting role in the human body. However, the human body lacks the ability to produce them in vivo. The limitations associated with the current sources of ω-3 fatty acids from animal and plant sources have led to increased interest in microbial production. Bacterial isolate 717 was identified as a potential high EPA producer. As an important step in the process development of the microbial PUFA production, the culture conditions at the bioreactor scale were optimised for the isolate 717 using a response surface methodology exploring the significant effect of temperature, pH and dissolved oxygen and the interaction between them on the EPA production. This optimisation strategy led to a significant increase in the amount of EPA produced by the isolate under investigation, where the amount of EPA increased from 9 mg/g biomass (33 mg/l representing 7.6 % of the total fatty acids) to 45 mg/g (350 mg/l representing 25 % of the total fatty acids). To avoid additional costs associated with extreme cooling at large scale, a temperature shock experiment was carried out reducing the overall cooling time from the whole cultivation process to 4 h only prior to harvest. The ability of the organism to produce EPA under the complete absence of oxygen was tested revealing that oxygen is not critically required for the biosynthesis of EPA but the production improved in the presence of oxygen. The stability of the produced oil and the complete absence of heavy metals in the bacterial biomass are considered as an additional benefit of bacterial EPA compared to other sources of PUFA. To our knowledge this is the first report of a bacterial isolate producing EPA with such high yields making the large-scale manufacture much more economically viable.     

Polyunsaturated fatty acid production by marine bacteria

Polyunsaturated fatty acids are important in maintaining human health. Limitations associated with current sources of ω-3 fatty acids and ω-6 fatty acids, from animal and plant sources, have led to increased interest in microbial production. Marine bacteria may provide a suitable alternative, although the isolation of production strains and the identification of operating conditions must be addressed before manufacturing processes become economically viable. Marine isolate 560 was identified as an eicosapentaenoic acid (EPA) producer via GC/MS. The isolate was initially identified as Vibrio cyclitrophicus by 16S rRNA sequencing. Statistically based experimental designs were applied to the optimisation of medium components and environmental factors for the production of EPA. A Plackett–Burman design was used to screen for the effect of temperature, pH, and media components. Subsequently, the concentrations of NaCl, yeast extract, and peptone, identified as significant factors, were optimised using a central composite design. The predicted optimal combination of media components for maximum EPA production (4.8 mg/g dry weight) was determined as 7.9 g/l peptone, 16.2 g/l NaCl, and 6.2 g/l yeast extract. On transfer of this process to bioreactor cultivation, where a range of pH and DO values were tested, the maximum amount of EPA produced increased to 7.5 mg/g dry weight and 10 % of the total fatty acid.     

Semi-industrial Scale Production of a New Yeast with Probiotic Traits, <Emphasis Type="Italic">Cryptococcus</Emphasis> sp. YMHS,Isolated from the Red Sea

A new yeast strain with promising probiotic traits was isolated from the Red Sea water samples. The isolate (YMHS) was subjected to genetic characterization and identified as Cryptococcus sp. Nucleotide sequence analysis of the rRNA gene internal transcribed spacer regions showed 95% sequence similarity between the isolate and Cryptococcus albidus. Cryptococcus sp. YMHS exhibited desirable characteristics of probiotic microorganisms; it has tolerance to low pH in simulated gastric juice, resistance to bile salts, hydrophobic characteristics, broad antimicrobial activity, and in vitro ability to degrade cholesterol. The isolate grew well in a semi-defined medium composed of yeast extract, glucose, KH₂PO₄, (NH₄)₂SO₄, and MgSO₄, yielding cell mass of 2.32 and 5.82 g/l in shake flask and in bioreactor cultures, respectively. Fed-batch cultivation, with controlled pH, increased the biomass gradually in culture, reaching 28.5 g/l after 32 h cultivation. Beside the feasible use as a probiotic, the new strain also could be beneficial in the development of functional foods or novel food preservatives. To our knowledge, this is the first report of yeast with probiotic properties isolated from the Red Sea.     

Fermentation of deproteinized cheese whey powder solutions to ethanol by engineered <Emphasis Type="Italic">Saccharomyces cerevisiae</Emphasis>: effect of supplementation with corn steep liquor and repeated-batch operation with biomass recycling by flocculation

The lactose in cheese whey is an interesting substrate for the production of bulk commodities such as bio-ethanol, due to the large amounts of whey surplus generated globally. In this work, we studied the performance of a recombinant Saccharomyces cerevisiae strain expressing the lactose permease and intracellular ß-galactosidase from Kluyveromyces lactis in fermentations of deproteinized concentrated cheese whey powder solutions. Supplementation with 10 g/l of corn steep liquor significantly enhanced whey fermentation, resulting in the production of 7.4% (v/v) ethanol from 150 g/l initial lactose in shake-flask fermentations, with a corresponding productivity of 1.2 g/l/h. The flocculation capacity of the yeast strain enabled stable operation of a repeated-batch process in a 5.5-l air-lift bioreactor, with simple biomass recycling by sedimentation of the yeast flocs. During five consecutive batches, the average ethanol productivity was 0.65 g/l/h and ethanol accumulated up to 8% (v/v) with lactose-to-ethanol conversion yields over 80% of theoretical. Yeast viability (>97%) and plasmid retention (>84%) remained high throughout the operation, demonstrating the stability and robustness of the strain. In addition, the easy and inexpensive recycle of the yeast biomass for repeated utilization makes this process economically attractive for industrial implementation.     

Production of eicosapentaenoic acid by the filamentous fungus Pythium irregulare

Because of the diversity of their lipids and fatty acid biosynthetic pathways, lower fungi may find utilization as sources of omega-3 or other polyunsaturated fatty acids (PUFA). Production of eicosapentaenoic acid (EPA) by the filamentous fungus, Pythium irregulare, has been demonstrated in 14-1 fermentors. Sweet whey permeate (lactose) was preferred over glucose as a substrate for production of a high-EPA-content lipid. Characterization of the lipid indicated that approximately 90% of the EPA was contained in the neutral lipid fraction. A specific productivity of 24.9 mg EPA/g dry biomass was achieved at 14°C, at which temperature the lipid contained 25.5% EPA and 54.2% PUFA. This is the highest mycelial EPA content for a fungal lipid that has been reported in the literature. Correspondence to: D. J. O'Brien     

Co-fermentation of carbon sources by Enterobacter aerogenes ATCC 29007 to enhance the production of bioethanol

We investigated the enhancement of bioethanol production in Enterobacter aerogenes ATCC 29007 by co-fermentation of carbon sources such as glycerol, glucose, galactose, sucrose, fructose, xylose, starch, mannitol and citric acid. Biofuel production increases with increasing growth rate of microorganisms; that is why we investigated the optimal growth rate of E. aerogenes ATCC 29007, using mixtures of different carbon sources with glycerol. E. aerogenes ATCC 29007 was incubated in media containing each carbon source and glycerol; growth rate and bioethanol production improved in all cases compared to those in medium containing glycerol alone. The growth rate and bioethanol production were highest with mannitol. Fermentation was carried out at 37 °C for 18 h, pH 7, using 50 mL defined production medium in 100 mL serum bottles at 200 rpm. Bioethanol production under optimized conditions in medium containing 16 g/L mannitol and 20 g/L glycerol increased sixfold (32.10 g/L) than that containing glycerol alone (5.23 g/L) as the carbon source in anaerobic conditions. Similarly, bioethanol production using free cells in continuous co-fermentation also improved (27.28 g/L) when 90.37 % of 16 g/L mannitol and 67.15 % of 20 g/L glycerol were used. Although naturally existing or engineered microorganisms can ferment mixed sugars sequentially, the preferential utilization of glucose to non-glucose sugars often results in lower overall yield and productivity of ethanol. Here, we present new findings in E. aerogenes ATCC 29007 that can be used to improve bioethanol production by simultaneous co-fermentation of glycerol and mannitol.     

Fermentation of biodiesel-derived glycerol by Bacillus amyloliquefaciens: effects of co-substrates on 2,3-butanediol production

Cultivation in glycerol instead of sugars inhibits 2,3-butanediol (2,3-BD) production by Bacillus amyloliquefaciens. In this study, we report that B. amyloliquefaciens readily produces 2,3-BD from biodiesel-derived glycerol in the presence of beet molasses as a co-substrate. Unexpectedly, the molasses stimulated 2,3-BD production and simultaneously reduced the duration of fermentation. Productivity of 2,3-BD was enhanced at the start of fermentation, and yields increased under continuous molasses supply. Subsequently, 2,3-BD production in molasses-supplemented fed-batch culture was observed. Prior to inoculation of fed-batch fermentation culture, 15 g/l of molasses was added to the bioreactor. After 6 h of incubation, the bioreactor was fed with a solution containing 80 % glycerol and 15 % molasses. The 2,3-BD concentration, yield, and productivity significantly improved, reaching 83.3 g/l, 0.42 g/g, and 0.87 g/l·h, respectively. To our knowledge, these results are the highest report for 2,3-BD fermentation from biodiesel-derived glycerol.     

An integrated process for the production of 1,3-propanediol,lactate and 3-hydroxypropionic acid by an engineered Lactobacillus reuteri

The process economy of food grade 1,3-propanediol (1,3-PD) production by GRAS organisms like Lactobacillus reuteri (L. reuteri), is negatively impacted by the low yield and use of expensive feedstocks. In order to improve the process economy, we have developed a multiproduct process involving the production of three commercially important chemicals, namely, 1,3-PD, lactate and 3-Hydroxypropionic acid (3-HP), by engineered L. reuteri. The maximum 1,3-PD and lactate titer of 41 g/L and 31 g/L, with a volumetric productivity of 1.69 g/L/h and 0.67 g/L/h were achieved, respectively. The maximum 3-HP titer of 5.2 g/L with a volumetric productivity of 1.3 g/L/h, was obtained by biotransformation using cells recovered from the repeated fed-batch process. The volumetric productivity of 1,3-PD obtained in this study is the highest ever reported for this organism. Further cost reduction can be achieved by using waste feedstocks like milk whey, biomass hydrolysate, and crude glycerol.     

Selective production of two diastereomers of disaccharide sugar alcohol, mannosylerythritol by Pseudozyma yeasts

Mannosylerythritol (ME) is the hydrophilic backbone of mannosylerythritol lipids as the most promising biosurfactants produced by different Pseudozyma yeasts, and has been receiving attention as a new sugar alcohol. Different Pseudozyma yeasts were examined for the sugar alcohol production using glucose as the sole carbon source. P. hubeiensis KM-59 highly produced a conventional type of ME, i.e., 4-O-β-d-mannopyranosyl-d-erythritol (4-ME). Interestingly, P. tsukubaensis KM-160 produced a diastereomer of 4-ME, i.e., 1-O-β-d-mannopyranosyl-d-erythritol (1-ME). In shake flask culture with 200 g/l of glucose, strain KM-59 produced 4-ME at a yield of 33.2 g/l (2.2 g/l/day of the productivity), while strain KM-160 produced 1-ME at 30.0 g/l (2.0 g/l/day). Moreover, the two strains were found to produce ME from glycerol; the maximum yields of 4-ME and 1-ME from 200 g/l of glycerol were 16.1 g/l (1.1 g/l/day) and 15.8 g/l (1.1 g/l/day), respectively. The production of 1-ME as the new diastereomer was further investigated in fed batch culture using a 5-l jar-fermenter. Compared to the flask culture, strain KM-160 gave three times higher productivity of 1-ME at 38.0 g/l (6.3 g/l/day) from glucose and at 31.1 g/l (3.5 g/l/day) from glycerol, respectively. This is the first report on the selective production of two diastereomers of ME, and should thus facilitate the functional development and application of the disaccharide sugar alcohol in the food and relative industries.     

Increase in the production of β-carotene in recombinant Escherichia coli cultured in a chemically defined medium supplemented with amino acids

Escherichia coli DH5α strain was selected as the recombinant host, and a chemically defined medium supplemented with amino acids was used instead of a complex medium for the efficient production of β-carotene. In a fed-batch culture using glycerol with a chemically defined medium supplemented with amino acids, the concentration, specific content, and productivity of β-carotene were 2,470 mg/l, 72 mg/g cells, and 77 mg/l h after 32 h, respectively. These values were, respectively, 43, 33, and 26 % higher than those obtained using the complex medium. This is the highest β-carotene production that has been reported among the recombinant cells to date.     

Statistical optimization of a culture medium for biomass and poly(3-hydroxybutyrate) production by a recombinant Escherichia coli strain using agroindustrial byproducts.

A statistically based Plackett-Burman screening design identified milk whey and corn steep liquor concentrations as well as ionic strength (based on phosphate buffer concentration) as the three main independent components of the culture medium that significantly (p < 0.05) influenced biomass and poly(3-hydroxybutyrate) (PHB) production in recombinant cells of Escherichia coli. This strain carries a plasmid encoding phb genes from a natural isolate of Azotobacter sp. Response surface methodology, using a central composite rotatable design, demonstrated that the optimal concentrations of the three components, defined as those yielding maximal biomass and PHB production in shaken flasks, were 37.96 g deproteinated milk whey powder/l, 29.39 g corn steep liquor/l, and 23.76 g phosphates/l (r2 = 0.957). The model was validated by culturing the recombinant cells in medium containing these optimal concentrations, which yielded 9.41 g biomass/l and 6.12 g PHB/l in the culture broth. Similar amounts of PHB were obtained following batch fermentations in a bioreactor. These results show that PHB can be produced efficiently by culturing the recombinant strain in medium containing cheap carbon and nitrogen sources.     

Production of erythritol and mannitol by Yarrowia lipolytica yeast in media containing glycerol

Glycerol is a by-product generated in large amounts during the production of biofuels. This study presents an alternative means of crude glycerol valorization through the production of erythritol and mannitol. In a shake-flasks experiment in a buffered medium, nine Yarrowia lipolytica strains were examined for polyols production. Three strains (A UV'1, A-15 and Wratislavia K1) were selected as promising producers of erythritol or/and mannitol and used in bioreactor batch cultures and fed-batch mode. Pure and biodiesel-derived crude glycerol media both supplemented (to 2.5 and 3.25?%) and not-supplemented with NaCl were applied. The best results for erythritol biosynthesis were achieved in medium with crude glycerol supplemented with 2.5?% NaCl. Wratislavia K1 strain produced up to 80.0?g?l(-1) erythritol with 0.49?g?g(-1) yield and productivity of 1.0?g?l(-1)?h(-1). Erythritol biosynthesis by A UV'1 and A-15 strains was accompanied by the simultaneous production of mannitol (up to 27.6?g?l(-1)). Extracellular as well as intracellular erythritol and mannitol ratios depended on the glycerol used and the presence of NaCl in the medium. The results from this study indicate that NaCl addition to the medium improves erythritol biosynthesis, and simultaneously inhibits mannitol formation.     

High-level production of Fc-fused kringle domain in Pichia pastoris

Recently, as a new non-immunoglobulin-based protein scaffold, a human kringle domain was successfully engineered toward biologically functional agonists and antagonists. In this study, the fed-batch cultivation conditions were optimized for enhanced production of an Fc-fused kringle domain (KD548-Fc) in Pichia pastoris. Fed-batch cultivations were performed in 5-l laboratory-scale bioreactors, and in order to find the optimal conditions for high-level production of KD548-Fc, several parameters including the initial carbon source (glycerol) concentration, temperature, and pH were investigated. When cells were cultivated at pH 4.0 and 25 °C with 9.5 % glycerol in the initial medium, the highest production yield (635 mg/l) was achieved with high productivity (7.2 mg/l/h). Furthermore, functional KD548-Fc was successfully purified from the culture broth using a simple purification procedure with high purity and recovery yield.     

ε-PolyLysine production from sugar cane molasses by a new isolates of Bacillus sp. and optimization of the fermentation condition

An attempt was made to use cane molasses as a culture medium for ε-PolyLysine (ε-PL) production by a natural bacterial isolate. The bacterium was identified as Bacillus sp., as confirmed by 16S rDNA sequence analysis. A BLAST result of the sequence indicated that the closest relative of this Bacillus BHU strain was B. thuringiensis, with 97 % homology. The molasses was found to be a better culture medium compared to commonly used culture media comprised of either glucose or glycerol as a carbon source. The various physicochemical parameters were studied for culture growth and polymer production, and were further optimized using response surface methodology (RSM). The correlation coefficient of the resulting model was found to be R ²?=?0.9828. The RSM predicted optimum conditions for ε-PL production (2.46 g/l) by the Bacillus strain was achieved by using molasses, 59.7 g/l; yeast extract, 15.2 mg/l; pH, 6.8 and fermentation time, 42 h at 30 °C. This study represents the first report on the potential application of cane molasses (a byproduct of sugarcane industries) as a culture medium for ε-PL production by Bacillus species. The specific Bacillus strain used in the present study can be exploited for developing a novel technology using inexpensive renewable resources for ε-PL production, a polymer of commercial interest.     

Metabolic flux analysis of Gluconacetobacter xylinus for bacterial cellulose production

Metabolic flux analysis was used to reveal the metabolic distributions in Gluconacetobacter xylinus (CGMCC no. 2955) cultured on different carbon sources. Compared with other sources, glucose, fructose, and glycerol could achieve much higher bacterial cellulose (BC) yields from G. xylinus (CGMCC no. 2955). The glycerol led to the highest BC production with a metabolic yield of 14.7 g/mol C, which was approximately 1.69-fold and 2.38-fold greater than that produced using fructose and glucose medium, respectively. The highest BC productivity from G. xylinus CGMCC 2955 was 5.97 g BC/L (dry weight) when using glycerol as the sole carbon source. Metabolic flux analysis for the central carbon metabolism revealed that about 47.96 % of glycerol was transformed into BC, while only 19.05 % of glucose and 24.78 % of fructose were transformed into BC. Instead, when glucose was used as the sole carbon source, 40.03 % of glucose was turned into the by-product gluconic acid. Compared with BC from glucose and fructose, BC from the glycerol medium showed the highest tensile strength at 83.5 MPa, with thinner fibers and lower porosity. As a main byproduct of biodiesel production, glycerol holds great potential to produce BC with superior mechanical and microstructural characteristics.     

Optimizing production of polyunsaturated fatty acids in Marchantia polymorpha cell suspension culture

Chlorophyll containing callus cells of Marchantia polymorpha are able to grow under dim illumination in the presence of an organic carbon source and retain the ability to produce polyunsaturated fatty acids (PUFA), including C(20) fatty acids. Highest PUFA production was achieved using 2,4-dichlorophenoxyacetic acid as growth regulator. Inoculum size, illumination intensity, organic carbon source, and ferrous ion are the major factors affecting PUFA productivity. Maximum PUFA productivity is attained under low light intensity, with a photon flux density ca. 20 micromol m(-2) s(-1). Optimal inoculum size and glucose concentration for PUFA production are 8-12% and 20-30 g l(-1), respectively. Ferrous ion can promote PUFA productivity by increasing the intracellular lipid content. Highest productivities for PUFA, arachidonic acid (ARA), and eicosapentaenoic acid (EPA) were 35.0+/-2.1, 6.7+/-0.4 and 6.6+/-0.4 mg l(-1) day(-1), respectively. PUFA production in the M. polymorpha culture is shown to be strongly growth-associated. Environmental stress (osmotic pressure) is ineffective in promoting PUFA productivity. Chitosan, an elicitor, also has no effect on intracellular PUFA content in cultured M. polymorpha cells.     

Novel fermentation process strengthening strategy for production of propionic acid and vitamin B12 by Propionibacterium freudenreichii

An efficient fermentation-strengthening approach was developed to improve the anaerobic production of propionic acid and vitamin B12 by co-fermentation with Propionibacterium freudenreichii. Vitamin B12 production from glucose resulted in relatively high productivity (0.35 mg/L h) but a low propionic acid yield (0.55 g/g). By contrast, glycerol gave a high propionic acid yield (0.63 g/g) but low productivity (0.16 g/L h). Co-fermentation of glycerol and glucose with a gradual addition strategy gave high yields (propionic acid: 0.71 g/g; vitamin B12: 0.72 mg/g) and productivities (propionic acid: 0.36 g/L h; vitamin B12: 0.36 mg/L h). Finally, the integrated feedstock and fermentation system strengthening strategy was demonstrated as an efficient method for the economic production of bio-based propionic acid and vitamin B12.     

Isolation, molecular identification and statistical optimization of culture condition for a new extracellular cholesterol oxidase-producing strain using response surface methodology

The current work details the screening of about 100 isolates from various soil samples, from which 1 isolate was finally selected based on the productivity of cholesterol oxidase. Further biochemical identification tests and 16S rRNA gene sequencing identified this isolate as Streptomyces badius. A preliminary culture media optimization was carried out using the initial screening method of Plackett-Burman. Then, a Box-Behnken design was employed to investigate the optimum concentrations of medium components and interactive effects of main variables on cholesterol oxidase production. The regression analysis showed a significant coefficient of determination (R ²) value (91 %), which was in close agreement ensuring a satisfactory adjustment of the proposed model. Maximal enzyme production (2.38 U/mL, i.e., approximately more than 100 % activity in the basal medium) was obtained at: temperature 35 °C; Tween 20 0.1 %; pH 6.5 and yeast extract 0.15 %. This two-stage statistical approach provided rapid identification and integration of key medium parameters for Streptomyces sp., resulting in high cholesterol oxidase production.     

Fed-batch fermentation to produce oligonucleotides from Kluyveromyces marxianus grown on whey

Oligonucleotides (ON) extracted from yeasts are used as antiviral agents, immunostimulators, and flavour enhancers. Fed-batch fermentation of cheese whey by Kluyveromyces marxianus was carried out to produce high biomass yields to extract ON. K marxianus was grown for 20 h in medium containing 5% (w/v) dehydrated whey, at 30°C (pH 4.5), with agitation (350 rpm), and under aeration (1.0–2.0 vvm). After 20 h, media containing 10–15% (w/v) of dehydrated whey were added at different flow rates (180–230 ml/h). Samples were analyzed at 6–8 h intervals for cell count, lactose consumption, and ethanol production. Maximum production of biomass (28.13 g/l), yield (0.58 g/g), productivity (2.42 g/l per h), and specific growth rate (0.63 1/h) were obtained when medium containing 15% (w/v) of whey was added at 180 ml/h under 2 vvm aeration. Fed-batch fermentation converted 95% of whey lactose into biomass.     

Simultaneous single-cell protein production and COD removal with characterization of residual protein and intermediate metabolites during whey fermentation by K. marxianus

Cheese whey fermentation with Kluyveromyces marxianus was carried out at 40 °C and pH 3.5 to examine simultaneous single-cell protein production and chemical oxygen demand (COD) removal, determine the fate of soluble whey protein and characterize intermediate metabolites. After 36 h of batch fermentation, the biomass concentration increased from 2.0 to 6.0 g/L with 55 % COD reduction (including protein), whereas soluble whey protein concentration decreased from 5.6 to 4.1 g/L. It was confirmed through electrophoresis (SDS-PAGE) that the fermented whey protein was different from native whey protein. HPLC and GC–MS analysis revealed a change in composition of organic compounds post-fermentation. High inoculum concentration in batch fermentation resulted in an increase in biomass concentration from 10.3 to 15.9 g/L with 80 % COD reduction (including protein) within 36 h with residual protein concentration of 4.5 g/L. In third batch fermentation, the biomass concentration increased from 7.3 to 12.4 g/L with 71 % of COD removal and residual protein concentration of 4.3 g/L after 22 h. After 22 h, the batch process was shifted to a continuous process with cell recycle, and the steady state was achieved after another 60 h with biomass yield of 0.19 g biomass/g lactose and productivity of 0.26 g/L h. COD removal efficiency was 78–79 % with residual protein concentration of 3.8–4.2 g/L. The aerobic continuous fermentation process with cell recycle could be applied to single-cell protein production with substantial COD removal at low pH and high temperature from cheese whey.