Biotechnological advantages of laboratory-scale solid-state fermentation with fungi

Despite the increasing number of publications dealing with solid-state (substrate) fermentation (SSF) it is very difficult to draw general conclusion from the data presented. This is due to the lack of proper standardisation that would allow objective comparison with other processes. Research work has so far focused on the general applicability of SSF for the production of enzymes, metabolites and spores, in that many different solid substrates (agricultural waste) have been combined with many different fungi and the productivity of each fermentation reported. On a gram bench-scale SSF appears to be superior to submerged fermentation technology (SmF) in several aspects. However, SSF up-scaling, necessary for use on an industrial scale, raises severe engineering problems due to the build-up of temperature, pH, O₂, substrate and moisture gradients. Hence, most published reviews also focus on progress towards industrial engineering. The role of the physiological and genetic properties of the microorganisms used during growth on solid substrates compared with aqueous solutions has so far been all but neglected, despite the fact that it may be the microbiology that makes SSF advantageous against the SmF biotechnology. This review will focus on research work allowing comparison of the specific biological particulars of enzyme, metabolite and/or spore production in SSF and in SmF. In these respects, SSF appears to possess several biotechnological advantages, though at present on a laboratory scale only, such as higher fermentation productivity, higher end-concentration of products, higher product stability, lower catabolic repression, cultivation of microorganisms specialized for water-insoluble substrates or mixed cultivation of various fungi, and last but not least, lower demand on sterility due to the low water activity used in SSF.     

Model for on-line moisture-content control during solid-state fermentation

In this study we describe a model that estimates the extracellular (nonfungal) and overall water contents of wheat grains during solid-state fermentation (SSF) with Aspergillus oryzae, using on-line measurements of oxygen, carbon dioxide, and water vapor in the gas phase. The model uses elemental balances to predict substrate dry matter losses from carbon dioxide measurements, and metabolic water production, water used in starch hydrolysis, and water incorporated in new biomass from oxygen measurements. Water losses caused by evaporation were calculated from water vapor measurements. Model parameters were determined using an experimental membrane-based model system, which mimicked the growth of A. oryzae on the wheat grains and permitted direct measurement of the fungal biomass dry weight and wet weight. The measured water content of the biomass depended heavily on the moisture content of the solid substrate and was significantly lower than the estimated values reported in the literature. The model accurately predicted the measured overall water content of fermenting solid substrate during fermentations performed in a 1.5-L scraped drum reactor and in a 35-L horizontal paddle mixer, and is therefore considered validated. The model can be used to calculate the water addition required to control the extracellular water content in a mixed solid-state bioreactor for cultivation of A. oryzae on wheat.     

Production of laccase from Trametes versicolor by solid-state fermentation using olive leaves as a phenolic substrate

The aim of the present study was to investigate whether olive leaves were feasible as a substrate for laccase production by the white-rot fungus Trametes versicolor FPRL 28A INI under solid-state fermentation conditions. Different experiments were conducted to select the variables that allow obtaining high levels of laccase activity. In particular, the effects of the initial moisture content, substrate particle size, supplementation with inorganic and organic nitrogen sources were evaluated. Highest laccase activity (276.62 ± 25.67 U/g dry substrate) was achieved with 80 % initial moisture content and 1.4–1.6 mm particle size of the substrate supplemented with yeast extract (1 % (w/w) nitrogen). Such a high activity was obtained without any addition of inducers.     

Protein enrichment of sweet potato residue with amylolytic yeasts by solid-state fermentation

Starchy agricultural wastes were inoculated with amylolytic yeasts for protein enrichment by solid-state fermentation. The moisture content of substrate was 65-69%, and water activity was equivalent to 0.98-0.99. The optimum conditions for protein enrichment were initial moisture content 65%, initial pH 4.5, a 1:1 mixture of ammonium sulfate and urea was incrementally added to the ferment with 1% added at zero time, 1% added at 24 h, and 0.5% added at 48 h, and incubation with amylolytic yeasts (1.0 x 10(10)/100 g substrate) at 30 degrees C for 2-3 days. The final product contained 16.11-20.82% protein.     

Fermentation of ang-kak in plastic bags and regulation of pigmentation by initial moisture content

A method of producing ang-kak (Chinese red rice) in plastic bags by Monascus sp. NP1 was developed. Advantages of the procedure are described. Fermentation of rice of various moisture contents gave results that agreed with previous findings that ang-kak could be produced only at a relatively low initial moisture level. The mechanism by which the initial substrate moisture content regulated pigmentation was clarified. It was found that glucoamylase activity increased with increase in initial substrate moisture content. Therefore at high moisture content, as high enzyme activity was produced, glucose was rapidly liberated in amounts that inhibited pigmentation. The sugar was then transformed to ethanol. Addition of various amounts of glucose to rice of low moisture content before fermentation confirmed that the sugar at certain concentration had an inhibitory effect on pigmentation.     

Streptomyces sp. TEM 33 possesses high lipolytic activity in solid-state fermentation in comparison with submerged fermentation

Solid-state fermentation (SSF) is a bioprocess that doesn’t need an excess of free water, and it offers potential benefits for microbial cultivation for bioprocesses and product development. In comparing the antibiotic production, few detailed reports could be found with lipolytic enzyme production by Streptomycetes in SSF. Taking this knowledge into consideration, we prefer to purify Actinomycetes species as a new source for lipase production. The lipase-producing strain Streptomyces sp. TEM 33 was isolated from soil and lipase production was managed by solid-state fermentation (SSF) in comparison with submerged fermentation (SmF). Bioprocess-affecting factors like initial moisture content, incubation time, and various carbon and nitrogen additives and the other enzymes secreted into the media were optimized. Lipase activity was measured as 1.74 ± 0.0005 U/g dry substrate (gds) by the p-nitrophenylpalmitate (pNPP) method on day 6 of fermentation with 71.43% final substrate moisture content. In order to understand the metabolic priority in SSF, cellulase and xylanase activity of Streptomyces sp. TEM33 was also measured. The microorganism degrades the wheat bran to its usable form by excreting cellulases and xylanases; then it secretes the lipase that is necessary for degrading the oil in the medium.     

Improved cellulase production by Botryosphaeria rhodina from OPEFB at low level moisture condition through statistical optimization

The response surface method was applied in this study to improve cellulase production from oil palm empty fruit bunch (OPEFB) by Botryosphaeria rhodina. An experimental design based on a two-level factorial was employed to screen the significant environmental factors for cellulase production. The locally isolated fungus Botryosphaeria rhodina was cultivated on OPEFB under solid-state fermentation (SSF). From the analysis of variance (ANOVA), the initial moisture content, amount of substrate, and initial pH of nutrient supplied in the SSF system significantly influenced cellulase production. Then the optimization of the variables was done using the response surface method according to central composite design (CCD). Botryosphaeria rhodina exhibited its best performance with a high predicted value of FPase enzyme production (17.95 U/g) when the initial moisture content was at 24.32%, initial pH of nutrient was 5.96, and 3.98 g of substrate was present. The statistical optimization from actual experiment resulted in a significant increment of FPase production from 3.26 to 17.91 U/g (5.49-fold). High cellulase production at low moisture content is a very rare condition for fungi cultured in solid-state fermentation.     

Characterization of the Factors that Influence Sinapine Concentration in Rapeseed Meal during Fermentation

We analyzed and compared the difference in sinapine concentration in rapeseed meal between the filamentous fungus, Trametes sp 48424, and the yeast, Saccharomyces cerevisiae, in both liquid and solid-state fermentation. During liquid and solid-state fermentation by Trametes sp 48424, the sinapine concentration decreased significantly. In contrast, the liquid and solid-state fermentation process by Saccharomyces cerevisiae just slightly decreased the sinapine concentration (P ≤ 0.05). After the solid-state fermented samples were dried, the concentration of sinapine in rapeseed meal decreased significantly in Saccharomyces cerevisiae. Based on the measurement of laccase activity, we observed that laccase induced the decrease in the concentration of sinapine during fermentation with Trametes sp 48424. In order to eliminate the influence of microorganisms and the metabolites produced during fermentation, high moisture rapeseed meal and the original rapeseed meal were dried at 90°C and 105°C, respectively. During drying, the concentration of sinapine in high moisture rapeseed meal decreased rapidly and we obtained a high correlation coefficient between the concentration of sinapine and loss of moisture. Our results suggest that drying and enzymes, especially laccase that is produced during the solid-state fermentation process, may be the main factors that affect the concentration of sinapine in rapeseed meal.     

Mass Production of Conidia of Penicillium frequentans,a Biocontrol Agent Against Brown Rot of Stone Fruits

Conidial production of Penicillium frequentans , a biocontrol agent of the fungal pathogen Monilinia laxa , was tested in liquid and solid-state fermentation. Conidial production of P. frequentans in solid-state fermentation was higher than in liquid-state fermentation. Solidstate fermentation was made in specially designed plastic bags (VALMIC ® ) containing peat:vermiculite (1:1 w/w). Addition of nutrients to the peat:vermiculite increased conidial production of P. frequentans , especially when lentil meal was added. The number of conidia obtained in this solid-state fermentation was maintained in the range of 10 8 -10 9 conidia g -1 from 5 to 120 days after inoculation. Germinability of these conidia was > 90% until 90 days of incubation and declined at 120 days. Optimal initial moisture content in the substrate was 30-40% (v/w). At lower moisture contents, significant reductions in conidial production and germinability were observed, particularly at 10% (v/w). Conidial production was similar when the substrate was inoculated with 10 5 , 10 6 or 10 7 conidia g -1 dry substrate. Fresh conidia produced by solid-state fermentation reduced the incidence of brown rot on plums by 75%.     

Solid-state refuse methanogenic fermentation: control and promotion by water addition

The efficacy of single water additions to promote the solid-state refuse methanogenic fermentation was examined with laboratory batch cultures. Initially, acidogenesis increased with increasing water addition although product inhibition was also apparent, particularly in low moisture content samples. With refuse columns, a moisture content increase from 55 to 75% (w/w) effected a 2.4-fold increase in the total volume of methane evolved during a 95-day incubation period although reduced evolution was apparent at the elevated moisture content of 80% (w/w). In general, the methane content of the evolved gases increased in response to increased water addition.     

无载体固定化酵母细胞木薯淀粉质原料酒精连续发酵研究

以木薯粉糖化液为发酵底物,在总发酵体积(有效)为15L的悬浮床生物反应器中,对一株粟酒裂殖酵母变异株进行一级和二级连续发酵研究。结果表明,二级连续发酵系统可明显改善一级系统的不足,并取得了平均流加糖液浓度150g/L,发酵强度为97g/L.h,流出液酒精浓度727g/L,残糖浓度374g./L,总糖利用率达90%的较好结果;整个系统在连续一个月的运行中从未发现染菌现象,发酵操作稳定。     

固态发酵降低上部低次烟叶中淀粉及蛋白质的含量

利用固态发酵的方法降低上部低次烟叶中淀粉和蛋白质的含量,并对发酵过程中的厌氧细菌和酵母的数量进行检测。采用单因素和正交试验对固态发酵的条件进行优化,结果表明:各因素对发酵上部低次烟叶影响显著性主次次序依次为发酵时间(C)、发酵温度(A)和发酵水分质量分数(B),固态发酵的最佳条件为A2B2C3,即温度45℃、水分质量分数50%、发酵时间9 d。在该发酵条件下,上部低次烟叶的淀粉降解率为20.41%,蛋白质降解率为12.35%。通过固态厌氧发酵的方法可取得较好的、短期内快速降解上部低次烟叶中淀粉和蛋白质含量的效果。     

Critical importance of moisture content of the medium in alpha-amylase production by Bacillus licheniformis M27 in a solid-state fermentation system

Summary A large reduction (about 30%–78%) is observed in the production of alpha-amylase by Bacillus licheniformis M27 in standardized wheat bran medium under solid-state fermentation when the moisture content of the medium is higher than the standardized value (65%). However, a surge in enzyme production in the first 24 h of fermentation is observed in media with 75% and 85% moisture. The role of decreased oxygen transfer in reducing enzyme tires by about 78% in the medium containing 95% moisture is evident, since the enzyme tire can be effectively increased by agitating the medium during fermentation. No such limitation in oxygen transfer is evident in medium containing 65% moisture even where incubated under static conditions or when the flask is capped by aluminum foil. The data indicate the critical importance of the moisture content of the medium in -amylase production by B. licheniformis M27 in solid-state fermentation systems. The results also have several implications of scientific and techno-economic importance and are useful in explaining some of the advantages of a solid-state fermentation system over the submerged fermentation process. Offprint requests to: B. K. Lonsane     

Heat and water transfer in a rotating drum containing solid substrate particles

In previous work we reported on the simulation of mixing behavior of a slowly rotating drum for solid-state fermentation (SSF) using a discrete particle model. In this investigation the discrete particle model is extended with heat and moisture transfer. Heat transfer is implemented in the model via interparticle contacts and the interparticle heat transfer coefficient is determined experimentally. The model is shown to accurately predict heat transfer and resulting temperature gradients in a mixed wheat grain bed. In addition to heat transfer, the addition and subsequent distribution of water in the substrate bed is also studied. The water is added to the bed via spray nozzles to overcome desiccation of the bed during evaporative cooling. The development of moisture profiles in the bed during spraying and mixing are studied experimentally with a water-soluble fluorescent tracer. Two processes that affect the water distribution are considered in the model: the intraparticle absorption process, and the interparticle transfer of free water. It is found that optimum distribution can be achieved when the free water present at the surface of the grains is quickly distributed in the bed, for example, by fast mixing. Alternatively, a short spraying period, followed by a period of mixing without water addition, can be applied. The discrete particle model developed is used successfully to examine the influence of process operation on the moisture distribution (e.g., fill level and rotation rate). It is concluded that the extended discrete particle model can be used as a powerful predictive tool to derive operating strategies and criteria for design and scale-up for mixed SSF and other processes with granular media.     

Mathematical modeling as a tool to investigate the design and operation of the zymotis packed-bed bioreactor for solid-state fermentation

Zymotis bioreactors for solid-state fermentation (SSF) are packed-bed bioreactors with internal cooling plates. This design has potential to overcome the problem of heat removal, which is one of the main challenges in SSF. In ordinary packed-bed bioreactors, which lack internal plates, large axial temperature gradients arise, leading to poor microbial growth in the end of the bed near the air outlet. The Zymotis design is suitable for SSF processes in which the substrate bed must be maintained static, but little is known about how to design and operate Zymotis bioreactors. We use a two-dimensional heat transfer model, describing the growth of Aspergillus niger on a starchy substrate, to provide guidelines for the optimum design and operation of Zymotis bioreactors. As for ordinary packed-beds, the superficial velocity of the process air is a key variable. However, the Zymotis design introduces other important variables, namely, the spacing between the internal cooling plates and the temperature of the cooling water. High productivities can be achieved at large scale, but only if small spacings between the cooling plates are used, and if the cooling water temperature is varied during the fermentation in response to bed temperatures.     

Optimization of xylanase production using inexpensive agro-residues by alkalophilic Bacillus subtilis ASH in solid-state fermentation

Alkalophilic Bacillus subtilis ASH produced high levels of xylanase using easily available inexpensive agricultural waste residues such as wheat bran, wheat straw, rice husk, sawdust, gram bran, groundnut and maize bran in solid-state fermentation (SSF). Among these, wheat bran was found to be best substrate. Xylanase production was highest after 72 h of incubation at 37 °C and at a substrate to moisture ratio of 1:2 (w/v). The inoculum level of 15% resulted in maximum production of xylanase. The enzyme production was stimulated by the addition of nutrients such as yeast extract, peptone and beef extract. In contrast, addition of glucose and xylose repressed the production of xylanase. The extent of repression by glucose (10%, w/v) was 81% and it was concentration-dependent. Supplementation of the medium with 4% xylose caused 59% repression. Under optimized conditions, xylanase production in SSF (8,964 U of xylanase/g dry wheat bran) was about twofold greater than in submerged fermentation. Thus, B. subtilis produced a very high level of xylanase in SSF using inexpensive agro-residues, a level which is much higher than that reported by any other bacterial isolate. Furthermore, the enzyme was produced at room temperature and with tap water without the addition of any mineral salt in SSF, leading to a marked decrease in the cost of xylanase production, which enhances its industrial potential.     

Temperature control in a continuously mixed bioreactor for solid-state fermentation

A continuously mixed, aseptic paddle mixer was used successfully for solid-state fermentation (SSF) with Aspergillus oryzae on whole wheat kernels. Continuous mixing improved temperature control and prevented inhomogeneities in the bed. Respiration rates found in this system were comparable to those in small, isothermal, unmixed beds, which showed that continuous mixing did not cause serious damage to the fungus or the wheat kernels. Continuous mixing improves heat transport to the bioreactor wall, which reduces the need for evaporative cooling and thus may help to prevent the desiccation problems that hamper large-scale SSF. However, scale-up calculations for the paddle mixer indicated that wall cooling becomes insufficient at the 2-m(3) scale for a rapidly growing fungus like Aspergillus oryzae. Consequently, evaporative cooling will remain important in large-scale mixed systems. Experiments showed that water addition will be necessary when evaporative cooling is applied in order to maintain a sufficiently high water activity of the solid substrate. Mixing is necessary to ensure homogeneous water addition in SSF. Automated process control might be achieved using the enthalpy balance. The enthalpy balance for the case of evaporative cooling in the paddle mixer was validated. This work shows that continuous mixing provides promising possibilities for simultaneous control of temperature and moisture content in solid-state fermentation on a large scale.     

Solid-state fermentation for the production of Monascus pigments from jackfruit seed

The aim of the present work was to investigate the feasibility of jackfruit seed powder as a substrate for the production of pigments by Monascus purpureus in solid-state fermentation (SSF). A pigment yield of 25ODUnits/g dry fermented substrate was achieved by employing jackfruit seed powder with optimized process parameters such as 50% initial moisture content, incubation temperature 30 degrees C, 9x10(4)spores/g dry substrate inoculum and an incubation period of seven days. The color of the pigments was stable over a wide range of pH, apparently due to the buffering nature of the substrate, which could be a significant point for its scope in food applications. To the best of our knowledge this is the first report on pigment production using jackfruit seed powder in solid-state fermentation (SSF).     

生物热对传统固态发酵菌群演替及其代谢影响的研究进展

解析传统固态发酵中产生的生物热对微生物菌群代谢的影响,是认识发酵机制、调控发酵过程、保证发酵效率的关键之一。固态发酵过程中,微生物菌群代谢活动所产生的生物热及传热效率低等问题引起微环境温度升高,进而影响微生物的生长与代谢。然而,关于传统固态发酵微生物受生物热的影响及其适应机制仍不明晰。因此,本文以传统固态发酵体系为研究对象,阐述持续生物热介导的高温对固态发酵过程中微生物群落演替和代谢功能的影响,并提出复杂群落中具有多层次调控微生物代谢以适应高温环境的方式,主要从微生物群体与个体层面介绍可能存在的耐热机制。了解生物热对传统固态发酵微生物的影响及潜在的耐热机制,有助于靶向调控发酵过程、强化高温发酵等,以满足未来的工业化需求。     

Intra-particle oxygen diffusion limitation in solid-state fermentation

Oxygen limitation in solid-state fermentation (SSF) has been the topic of modeling studies, but thus far, there has been no experimental elucidation on oxygen-transfer limitation at the particle level. Therefore, intra-particle oxygen transfer was experimentally studied in cultures of Rhizopus oligosporus grown on the surface of solid, nutritionally defined, glucose and starch media. The fungal mat consisted of two layers--an upper layer with sparse aerial hyphae and gas-filled interstitial pores, and a dense bottom layer with liquid-filled pores. During the course of cultivation ethanol was detected in the medium indicating that oxygen was depleted in part of the fungal mat. Direct measurement of the oxygen concentrations in the fungal mat during cultivation, using oxygen microelectrodes, showed no oxygen depletion in the upper aerial layer, but revealed development of steep oxygen concentration gradients in the wet bottom layer. Initially, the fungal mat was fully oxygenated, but after 36.5 hours oxygen was undetectable at 100 microm below the gas-liquid interface. This was consistent with the calculated oxygen penetration depth using a reaction-diffusion model. Comparison of the overall oxygen consumption rate from the gas phase to the oxygen flux at the gas-liquid interface showed that oxygen consumption of the microorganisms occurred mainly in the wet part of the fungal mat. The contribution of the aerial hyphae to overall oxygen consumption was negligible. It can be concluded that optimal oxygen transfer in SSF depends on the available interfacial gas-liquid surface area and the thickness of the wet fungal layer. It is suggested that the moisture content of the matrix affects both parameters and, therefore, plays an important role in optimizing oxygen transfer in SSF cultures.