Conversion of food industrial wastes into bioplastics

The usage of plastics in packaging and disposable products, and the generation of plastic waste, have been increasing drastically. Broader usage of biodegradable plastics in packaging and disposable products as a solution to environmental problems would heavily depend on further reduction of costs and the discovery of novel biodegradable plastics with improved properties. In the authors’ laboratories, various carbohydrates in the growth media, including sucrose, lactic acid, butyric acid, valeric acid, and various combinations of butyric and valeric acids, were utilized as the carbon (c) sources for the production of bioplastics byAlcaligenes eutrophus. As the first step in pursuit of eventual usage of industrial food wastewater as nutrients for microorganisms to synthesize bioplastics, the authors investigated the usage of malt wastes from a beer brewery plant as the C sources for the production of bioplastics by microorganisms. Specific polymer production yield by A. Latus DSM 1124 increased to 70% polymer/cell (g/g) and 32g/L cell dry wt, using malt wastes as the C source. The results of these experiments indicated that, with the use of different types of food wastes as the C source, different polyhydroxyal-kanoate copolymers could be produced with distinct polymer properties.     

Production of specific copolymers of polyhydroxyalkanoates from industrial waste

Polyhydroxyalkanoates, biodegradable plastics with the desired physical and chemical properties of conventional synthetic plastics, are extensively investigated. In this study, specific bacterial strains produced specific copolymers from food waste. Copolymers of HB and HV (poly[3-hydroxybutyrate-co-3-hydroxyvalerate]) were obtained using various ratios of butyric acid (C₄) and valeric acid (C₅) as carbon sources. The C₄ to C₅ ratio affected the melting points of the copolymers. Melting and glass transition temperatures and many other thermal properties are important parameters relative to in-service polymer applications. Higher ratios of butyrate to valerate gave higher melting points. When a mixed culture of activated sludge was employed to produce copolymers using food wastes as nutrients, the obtained copolymers showed various monomer compositions. Copolymers with a higher portion of HV were obtained using soy waste; copolymers with less HV were obtained using malt wastes. Pure strains, (i.e., Alcaligenes latus DSM 1122, and DSM 1124, Staphylococcus spp., Klebsiella spp.) produced specific copolymers from food waste. Only Klebsiella spp. produced different copolymers; the ratios of HB:HV were 93:7 and 79:21 from malt waste and soy waste, respectively. The other strains produced polymers of 100% HB. Selecting industrial food wastes as carbon sources can further reduce the cost of producing copolymers. Open Laboratory of Chirotechnology of the Institute of Molecular Technology for Drug Discovery and Synthesis The University Grants Committee Area of Excellence Scheme, Hong Kong     

Microbial production of polyhydroxyalkanoates by bacteria isolated from oil wastes

A Gram-positive coccus-shaped bacterium capable of synthesizing higher relative molecular weight (M _r), polyhydroxybutyrate (PHB) was isolated from sesame oil and identified as Staphylococcus epidermidis (by Microbial ID, Inc., Newark, NJ). The experiment was conducted by shake flask fermentation culture using media containing fructose. Cell growth up to a dry mass of 2.5 g/L and PHB accumulation up to 15.02% of cell dry wt was observed. Apart from using single carbohydrate as a sole carbon source, various industrial food wastes including sesame oil, ice cream, malt, and soya wastes were investigated as nutrients for S. epidermidis to reduce the cost of the carbon source. As a result, we found that by using malt wastes as nutrient for cell growth, PHB accumulation of S. epidermidis was much better than using other wastes as nutrient source. The final dried cell mass and PHB production using malt wastes were 1.76 g/L and 6.93% polymer/cells (grams/gram), and 3.5 g/L and 3.31% polymer/cells (grams/gram) in shake flask culture and in fermentor culture, respectively. The bacterial polymer was characterized by ¹H-nuclear magnetic resonance (NMR), ¹³C-NMR, Fourier transform infrared, and differential scanning calorimetry. The results show that with different industrial food wastes as carbon and energy sources, the same biopolymer (PHB) was obtained. However, the use of sesame oil as the carbon source resulted in the accumulation of PHB with a higher melting point than that produced from other food wastes as carbon sources by this organism under similar experimental conditions.     

Production of polyhydroxybutyrate by Bacillus species isolated from municipal activated sludge

Plastic wastes are considered to be severe environmental contaminants causing waste disposal problems. Widespread use of biodegradable plastics is one of the solutions, but it is limited by high production cost. Biologic wastewater treatment generates large quantities of biomass as activated sludge. Only a few reports focus on the potential of utilizing resident Bacillus species from activated sludge in polyhydroxbutyrate (PHB) production as well as the production of PHB from food wastes. They have attractive properties such as short generation time, absence of endotoxins, and secretion of both amylases and proteinases that can well utilize food wastes for nutrients, which can further reduce the cost of production of polyhydroxyalkanoates (PHAs). Two PHA-producing strains, HF-1 and HF-2, were isolated from activated sludge. HF-1 outperfomed HF-2 in terms of growth and PHB production in hydrolyzed soy and malt wastes. The isolated bacteria was characterized by DNA sequence alignment. Cell extracts of HF-1 were also compared to Bacillus megaterium cell extracts on sodium dodecyl sulfate polyacrylamide gel electrophoresis. The biopolymers accumulated were analyzed by gas chromatography, nuclear magnetic resonance, and Fourier transform infrared methods.     

Production of PHAs from agricultural waste material

Polyhydroxyalkanoates (PHAs) are biodegradable substitutes to fossil fuel plastics that can be produced from renewable raw materials such as saccharides, alcohols and low-molecular-weight fatty acids. They are completely degradable to carbon dioxide and water through natural microbiological mineralization. Consequently, neither their production nor their use or degradation have a negative ecological impact. By keeping closed the cycle of production and re-use, PHAs can enable at least part of the polymer-producing industry to switch from ecologically harmful end-of-the-pipe production methods towards sounder technologies. Up to now such polyesters have been produced biotechnologically from refined raw materials (e.g. glucose and sodium propionate), but they can as well be produced much cheaper from agricultural waste materials (e.g. molasses, maltose, glycerol phase from biodiesel production, whey), as long as these materials have a known composition and are available in appropriate quantities. Yield factors and specific rates for growth and PHA accumulation are shown for 3 strains of Alcaligenes latus for different agricultural waste carbon sources.     

Conversion of food industrial wastes into bioplastics with municipal activated sludge

Plastics have become an integral part of our contemporary life because of many desirable properties including durability and resistance to degradation. However, these non-degradable, petrochemicals-derived plastics accumulate in the environment at a rate of 25 million tons per year. Recently there is an interest in the development of a class of microbially produced bioplastics, e.g., polyhydroxyalkanoates (PHAs) which retain the desired physical and chemical properties of conventional synthetic plastics. Broader usage of biodegradable plastics in packaging and disposable products as a solution to the environmental problem would heavily depend on further reduction of costs and the discovery of novel biodegradable plastics with improved properties. In this paper, the microbial production of PHAs by activated sludge utilizing food industrial wastes is reported. The melting points of the products as well as the co-polymer composition of the products investigated by GC and NMR were compared. By use of activated sludge to convert the carbon source into PHAs not only environment-friendly bioplastics are produce, but also part of the problem of the disposal of municipal activated sludge is solved. The selection of food industrial waste as carbon resource can also further reduce the cost of production of PHAs.     

Construction of recombinant Escherichia coli strais for production of poly-(3-hydroxybutyrate-co-3-hydroxyvalerate)

Plastic wastes constitute a worldwide environmental problem, and the demand for biodegradable plastics has become high. One of the most important characteristics of microbial polyesters is that they are thermoplastic with environmentally degradable properties. In this study, pUC 19/PHA was cloned and transformed into three different Escherichia coli strains. Among the three strains that were successfully expressed in the production of polyhydroxyalkanoates (PHA), E. coli HMS174 had the highest yield in the production of poly-(3-hydroxybutyrate-co-3-hydroxyvalerate) (P[HB-HV]). The cell dry weight and PHA content of recombinant HMS174 reached as high as 10.27 g/L and 43% (w/w), respectively, in fed-batch fermentor culture. The copolymer of PHA, P(HB-HV), was found in the cells, and the biopolymers accumulated were identified and analyzed by gas chromatography, proton nuclear magnetic resonance spectroscopy, and differential scanning calorimetry. We demonstrated clearly that the E. coli host for PHA production has to be carefully selected to obtain a high yield. The results obtained indicated that a superior E. coli with high PHA production can be constructed with a desirable ratio of P(HB-HV), which has potential applications in industry and medicine.     

Identification and Quantification of Polycyclic Aromatic Hydrocarbons in Polyhydroxyalkanoates Produced from Mixed Microbial Cultures and Municipal Organic Wastes at Pilot Scale

Polyhydroxyalkanoates (PHAs) are well-known biodegradable plastics produced by various bacterial strains, whose major drawback is constituted by the high cost of their synthesis. Producing PHAs from mixed microbial cultures and employing organic wastes as a carbon source allows us to both reduce cost and valorize available renewable resources, such as food waste and sewage sludge. However, different types of pollutants, originally contained in organic matrices, could persist into the final product, thus compromising their safety. In this work, the exploitation of municipal wastes for PHA production is evaluated from the environmental and health safety aspect by determining the presence of polycyclic aromatic hydrocarbons (PAHs) in both commercial and waste-based PHA samples. Quantification of PAHs by gas chromatography-mass spectrometry on 24 PHA samples obtained in different conditions showed very low contamination levels, in the range of ppb to a few ppm. Moreover, the contaminant content seems to be dependent on the type of PHA stabilization and extraction, but independent from the type of feedstock. Commercial PHA derived from crops, selected for comparison, showed PAH content comparable to that detected in PHAs derived from organic fraction of municipal solid waste. Although there is no specific regulation on PAH maximum levels in PHAs, detected concentrations were consistently lower than threshold limit values set by regulation and guidelines for similar materials and/or applications. This suggests that the use of organic waste as substrate for PHA production is safe for both the human health and the environment.     

Production of lactic acid from food wastes

Conversion of food wastes into lactic acid by simultaneous saccharification and fermentation (SSF) was investigated. The process involves saccharification of the starch component in food wastes by a commercial amylolytic enzyme preparation (a mixture of amyloglucosidase, α-amylase, and protease) and fermentation by Lactobacillus delbrueckii. The highest observed overall yield of lactic acid in the SSF was 91% of theoretical. Lactic acid concentration as high as 80 g/L was attainable in 48 h of the SSF. The optimum operating conditions for the maximum productivity were found to be 42°C and pH 6.0. Without supplementation of nitrogen-containing nutrients, the lactic acid yield in the SSF decreased to 60%: 27 g/L of lactic acid from 60 g/L of food waste. The overall performance of the SSF, however, was not significantly affected by the elimination of mineral supplements.     

Bacterial production of PHA from lactose and cheese whey permeate

Due to the large availability of agro-industry wastes containing potentially exploitable substrates, such as whey from dairy industry, a study on the bacterial conversion of lactose and whey permeate to poly(β-hydroxyalkanoate) (PHA) was undertaken. A first approach was carried out on culture collection strains. Among a number of strains tested, Hydrogenophaga pseudoflava DSM 1034 and Sinorhizobium meliloti 41 were found to grow on lactose and produce PHA. These findings suggested to investigate among a wider range of microorganisms by directly isolating new strains from soil. A number of soil bacteria were first isolated on a minimal medium containing lactose as unique carbon source and PHA-accumulating traits were then investigated. Three isolates, identified by 16S rDNA sequence analysis as Sinorhizobium sp., Bacillus megaterium and Bacillus sp., were selected for their efficient growth and PHA production using lactose as carbon source. The same strains were also tested for their ability to accumulate PHA by direct fermentation of whey and whey permeate. Our results suggest that production of the polymer from cheese whey or whey permeate may be possible, although further research is needed to determine whether these microorganisms have the potential for commercial production of such biodegradable polymers.     

Recent advances in polyhydroxyalkanoate production by mixed aerobic cultures: from the substrate to the final product

Numerous bacteria have been found to exhibit the capacity for intracellular polyhydroxyalkanoates (PHA) accumulation. Current methods for PHA production at the industrial scale are based on their synthesis from microbial isolates in either their wild form or by recombinant strains. High production costs are associated with these methods; thus, attempts have been made to develop more cost-effective processes. Reducing the cost of the carbon substrates (e.g., through feeding renewable wastes) and increasing the efficiency of production technologies (including both fermentation and downstream extraction and recovery) are two such examples of these attempts. PHA production processes based on mixed microbial cultures are being investigated as a possible technology to decrease production costs, since no sterilization is required and bacteria can adapt quite well to the complex substrates that may be present in waste material. PHA accumulation by mixed cultures has been found under various operational conditions and configurations at both bench-scale and full-scale production. The process known as "feast and famine" or as "aerobic dynamic feeding" seems to have a high potential for PHA production by mixed cultures. Enriched cultures submitted to a transient carbon supply can synthesize PHA at levels comparable to those of pure cultures. Indeed, the intracellular PHA content can reach around 70% of the cell dry weight, suggesting that this process could be competitive with pure culture PHA production when fully developed. Basic and applied research of the PHA production process by mixed cultures has been carried out in the past decade, focusing on areas such as microbial characterization, process configuration, reactor operational strategies, process modeling and control, and polymer characterization. This paper presents a review of the PHA production process with mixed cultures, encompassing the findings reported in the literature as well as our own experimental results in relation to each of these areas.     

以葡萄糖为碳源合成生物降解性聚酯的研究

利用从油田土壤中筛选的菌种ＤＧ１７ 以葡萄糖为碳源通过微生物发酵法合成了具有不同结构单元的新型生物可降解性聚合物———聚羟基脂肪酸酯（ＰＨＡｓ） ．初步研究了ＤＧ１７ 以葡萄糖为碳源的生物合成规律,并借助ＧＣ、ＮＭＲ 等分析手段对合成的聚合物进行了结构的分析表征,另外还研究了ＰＨＡｓ 的活性污泥降解情况．研究表明,在限氮条件下,只有碳氮比高于５后,ＤＧ１７ 才能在其体内合成ＰＨＡｓ．在过量碳源的存在下,氮磷比低,得到的聚合物是一种具长侧链的聚（ 羟基辛酸 ｃｏ 羟基癸酸） 的共聚物,为一种热塑性弹性体．在硫酸铵浓度为０－５ｇ／Ｌ,碳氮比为２０ 条件下合成的Ｐ（ＨＯ ｃｏ ＨＤ） 热塑性弹性体的数均分子量为１－１６ ×１０ － ５ ,分子量分散指数为２－４３ ．其玻璃化温度及熔融温度分别为Ｔｇ ＝ － ５２ ℃,Ｔｍ ＝ ５０ ℃．氮磷比高,则合成热塑性塑料ＰＨＢ．结果表明培养基中氮源与磷酸盐的相对浓度是影响ＤＧ１７ 生物合成路径的重要条件．     

Production of biological polymers from organic wastes

Biologically-produced polymers, from microbial fermentation are naturally biodegradable and are potential environment-friendly substitutes for some synthetic plastics. However, broader applications are restricted by the high production costs and limitations in physical and mechanical properties. In this study, activated sludge bacteria in a conventional wastewater treatment system treating a wastewater that contained organic pollutants, were induced by nitrogen deficiency to accumulate intracellular storage polymers, which can be extracted as a low-cost source of biodegradable plastics. Chromatographic analysis of the extracted polymers revealed a composition of poly-hydroxyalkanoate and a number of related co-polymers. Alcaligene spp. in the activated sludge microbial consortium was identified as the main genus accumulated these polymers. When the C:N ratio was increased from 20 to 140, the specific polymer yield increased to a maximum of 0.39 g polymer/g dry cell while specific growth yield decreased to 0.26 g dry cell/g carbonaceous matter consumed. The highest overall polymer production yield of 0.11 g polymer/g carbonaceous matter consumed was achieved when the C:N ratio was maintained at a nitrogen-deficient level of 100. The specific polymer yield in the isolated Alcaligene spp. cells were as high as 0.7 g polymer/g dry cell mass. The composition of the co-polymers, and hence the physical and mechanical properties, could be controlled by manipulating the influent organic compositions.     

Optimal production of polyhydroxyalkanoates in activated sludge biomass

Polyhydroxyalkanoates (PHAs) have been recognized as good candidates for biodegradable plastics, but their high price compared with conventional plastics has limited their use. In this study, actiated sludge microorgan isms from a conventional wastewater treatment process were induced, bycontrol-lingthe carbon: nitrogen (C:N) ratioin the reacorliquor, toaccumulate PHAs. In addition, an intermittent nitrogen feeding program was established to optimize the volumetric PHA productivity in a wastewater treatment process. The optimal overall polymer production yield of 0.111 g of polymer/g of carbonaceous substrate consumed was achieved under a C:N ratio of 96:1 by feeding nitrogen in the reactor liquor onceevery four cycles. At the same time, the amount of excess sludge generated from the wastewater treatment process was reduced by22.9%.     

Production of polyhydroxyalkanoate from sesame seed wastewater by sequencing batch reactor cultivation process of Haloferax mediterranei

Due to the high cost of bioplastic production, sesame wastewater, generated from the sesame seed hulling process, was investigated to be used as inexpensive and renewable carbon source for the production of biodegradable polyhydroxyalkanoate (PHA) by extreme Haloferax mediterranei. The sesame wastewater (SWW) was hydrolyzed using different concentrations of hydrochloric acid (0.4. 1.00 and 2.00 M) at different period of times (15, 60 and 90 min). The concentration of salt (NaCl) and nitrogen source (NH₄Cl and yeast) required for H. mediterranei cells growth and the accumulation of PHA biopolymer was optimized. A maximum 0.53 g/L concentration of PHA was achieved when the SWW extract media was supplemented with 100 g/L NaCl and 6.0 g/L yeast extract. The cultivation was scaled-up using sequencing batch reactor (SBR) fermentation under non-sterile conditions. The SBR results showed that SWW needs an auxiliary carbon source to obtain high PHA production. Consequently, the system fed with SWW and glucose produced higher PHA (20.9 g/L) than the system fed with SWW.     

Production of Polyhydroxyalkanoates (PHAs) by Vibrio alginolyticus Strains Isolated from Salt Fields

Vibrio alginolyticus is a halophilic organism usually found in marine environments. It has attracted attention as an opportunistic pathogen of aquatic animals and humans, but there are very few reports on polyhydroxyalkanoate (PHA) production using V. alginolyticus as the host. In this study, two V. alginolyticus strains, LHF01 and LHF02, isolated from water samples collected from salt fields were found to produce poly(3-hydroxybutyrate) (PHB) from a variety of sugars and organic acids. Glycerol was the best carbon source and yielded the highest PHB titer in both strains. Further optimization of the NaCl concentration and culture temperature improved the PHB titer from 1.87 to 5.08 g/L in V. alginolyticus LHF01. In addition, the use of propionate as a secondary carbon source resulted in the production of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV). V. alginolyticus LHF01 may be a promising host for PHA production using cheap waste glycerol from biodiesel refining.     

Construction of recombinant Bacillus subtilis for production of polyhydroxyalkanoates

Polyhydroxyalkanoates (PHAs) are polyesters of hydroxyalkanoates synthesized by numerous bacteria as intracellular carbon and energy storage compounds and accumulated as granules in the cytoplasm of cells. In this work, we constructed two recombinant plasmids, pBE2C1, and pBE2C1AB, containing one or two PHA synthse, genes, respectively. The two plasmids were inserted into Bacillus subtilis DB104 to generate modified strains, B. subtilis/pBE2C1 and B. subtilis/pBE2C1AB. The two recombinants strains were subjected to fermentation and showed PHA accumulation, the first reported example of mcl-PHA production in B. subtilis. Gas Chromatography analysis identified the compound produced by B. subtilis/pBE2C1 to be a hydroxydecanoate-co-hydroxydodecanoate (HD-co-HDD) polymer whereas that produced by B. subtilis/pBE2C1AB was a hydroxybutyrate-co-hydroxyde-canoate-co-hydroxydodecanoate (HB-HD-HDD) polymer.     

Recent progress in biodegradable polymers and nanocomposite-based packaging materials for sustainable environment

Plastic-based materials are frequently used in packaging and can be seen universally in both the developed and developing societies. At present, most of the currently used food packaging materials are nondegradable and are creating serious environmental problems. New technologies are being explored and developed to study the complex interaction between the food packaging materials and food. For example, nanocomposite of cellulose constitutes environmentally friendly packaging, which is easily recycled by combustion and requires low power consumption in production. There are several such biodegradable materials which are available at a low price, have good mechanical properties and allow disposal in the soil. This is advantageous because biological degradation produces only carbon dioxide, water, and inorganic compounds to name a few. It has also been discovered that biodegradable plastics made of such materials can be disposed of together with organic waste. The widespread use of biopolymers in the place of standard plastics would help to reduce the weight of waste. Therefore, biodegradable materials take part in the natural cycle “from nature to nature” and play an important role for environmental sustainability. So, in this article, we briefly summarize the different characteristic of biodegradable polymers being used in food packaging applications.     

Optimization of l -(+)-lactic acid production using pelletized filamentous Rhizopus oryzae NRRL 395

Lactic acid is used as a food additive for flavor and preservation and a precursor in the development of poly-lactic acid, a product used to make biodegradable plastics and textiles. Rhizopus oryzae NRRL 395 is known to be a strain that produces optically pure l-(+)-lactic acid. The morphology of Rhizopus cultures is complex, forming filamentous, clumps, and pellet mycelia. Different morphology growth has significant effects on lactic acid production. In bioreactors, the filamentous or clump mycelia increase the viscosity of the medium, wrap around impellers, and block the nutrient transportation, leading to a decrease in production efficiency and bioreactor performance. Growing fungi in pellet form can significantly improve these problems. In this study, factors that affect lactic acid production in pelletized flask cultures using R. oryzae NRRL 395 were investigated in detail. Completely randomized designs were used to determine the influence of culture temperature, time, concentration of glucose, and inoculum size. Lactic acid fermentation using clump and pellet morphologies were performed in a 5 L fermentor at the optimal values obtained from flask culture. Finally, fed-batch culture was used to enhance the lactate concentration in broth. The final lactate concentration of fed-batch culture reached 92 g/L. The data presented in the article can provide useful information on optimizing lactic acid production using alternative source materials.     

Model-Based Nutrient Feeding Strategies for the Increased Production of Polyhydroxybutyrate (PHB) by <Emphasis Type="Italic">Alcaligenes latus</Emphasis>

Polyhydroxyalkanoates (PHAs) are biodegradable polymers which are considered as an effective alternative for conventional plastics due to their mechanical properties similar to the latter. However, the widespread use of these polymers is still hampered due to their higher cost of production as compared to plastics. The production cost could be overcome by obtaining high yields and productivity. The goal of the present research was to enhance the yield of polyhydroxybutyrate (PHB) with the help of two simple fed-batch cultivation strategies. In the present study, average batch kinetic and substrate limitation/inhibition study data of Alcaligenes latus was used for the development of PHB model which was then adopted for designing various off-line nutrient feeding strategies to enhance PHB accumulation. The predictive ability of the model was validated by experimental implementation of two fed-batch strategies. One such dynamic strategy of fed-batch cultivation under pseudo-steady state with respect to nitrogen and simultaneous carbon feeding strategy resulted in significantly high biomass and PHB concentration of 39.17 g/L and 29.64 g/L, respectively. This feeding strategy demonstrated a high PHB productivity and PHB content of 0.6 g/L h and 75%, respectively, which were remarkably high in comparison to batch cultivation. The mathematical model can also be employed for designing various other nutrient feeding strategies.