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Characterisation of six supergene ferromanganese ore samples revealed that P was hosted by several different Fe and Mn oxides. Goethite had the highest (up to >1% or higher) and highest mean (up to 0.32%) P contents, then cryptomelane-hollandite (mean up to 0.12% P) and nsutite-pyrolusite (mean up to 0.14% P). When present in the same sample, nsutite had a higher mean P content than pyrolusite. Phosphate minerals were not detected in the samples. P deportment was variable with deposit, deposit type and within individual mineral grains. EPMA showed that P content is elevated in cryptomelane with higher Mn/(Fe + Al + Si) ratios and in todorokite with lower Mn/(Fe + Al + Si) ratios. The results show that higher phosphorus supergene ferromanganese ores with considerable cryptomelane and nsutite contents are likely to have multi-phase Fe-P and Mn-P deportment. The propensity for very fine-scale intergrowths of goethite and Mn oxides ± aluminosilicates in some ore types means that reliable characterisation of P deportment is critical in informing potential P-reduction pathways for ferroalloy feedstocks. P was most probably incorporated into Mn oxides via near-surface adsorption via complexation with cations such as Ca or Mg in todorokite, but the presence of structural P cannot be precluded in cryptomelane and nsutite. [ABSTRACT FROM AUTHOR]

Within the circular bioeconomy the production of optically pure LA from 2nd generation feedstocks would be ideal but it is very challenging. In this paper genetically engineered Escherichia coli strains were created to resolve racemic LA solutions synthesised and produced from the fermentation of organic waste or ensiled grass. Refining LA racemic mixtures into either a D- or L-LA was achieved by cells being able to consume one LA isomer as a sole carbon and energy source while not being able to consume the other. A D-LA refining strain JSP0005 was grown on fermented source-sorted organic household waste and different grass silage leachates, which are 2nd generation feedstocks containing up to 33 g/L lactic acid racemate. In all growth experiments, L-LA was completely removed leaving D-LA as the only LA stereoisomer, i.e. resulting in optically pure D-LA, which also increased by as much as 248.6 % from its starting concentration, corresponding to 38 g/L. The strains resulting from this study are a promising first step towards a microbial based LA biorefining process. [Display omitted] • Genetically engineered Escherichia coli strains yield optically pure lactic acid from racemic mixtures. • These strains could allow racemic lactic acid solutions to be obtained from cheap and abundant 2nd generation feedstocks. • D‐lactic acid was produced while all L-lactic acid was removed from grass silage leachates and fermented organic wastes. [ABSTRACT FROM AUTHOR]

Previous investigations of whether readers make predictions about the full identity of upcoming words have focused on the extent to which there are processing consequences when readers encounter linguistic input that is incompatible with their expectations. To date, eye-movement studies have revealed inconsistent evidence of the processing costs that would be expected to accompany lexical prediction. This study investigated whether readers' lexical predictions were observable during or downstream from their initial point of activation. Three experiments assessed readers' eye movements to predictable and unpredictable words, and then to subsequent downstream words, which probed the lingering activation of previously expected words. The results showed novel evidence of processing costs for unexpected input but only when supported by a plausible linguistic environment, suggesting that readers could strategically modulate their predictive processing. However, there was limited evidence that their lexical predictions affected downstream processing. The implications of these findings for understanding the role of prediction in language processing are discussed. [ABSTRACT FROM AUTHOR]

Despite the heterogeneity associated with extracellular vesicle (EV) biogenesis pathways and the physiological state of the EV parental cells, standardization of EV manufacturing workflows could contribute to increase intra- and inter-batch reproducibility. Reaching effective EV doses for clinical use in cardiac regenerative settings requires large-scale platforms for EV production and isolation and/or strategies that maximize EV secretion per cell. While bioreactors – such as stirred-tank or vertical-wheel bioreactors – are envisioned as scalable platforms to sustain cell secretion of EVs, membrane-based processes can allow continuous and large-scale isolation of EVs. Both single-vesicle analysis and omics approaches can be relevant tools to dissect the mechanism of action of EVs in cardiac repair. For the past two decades researchers have linked extracellular vesicle (EV)-mediated mechanisms to various physiological and pathological processes in the heart, such as immune response regulation, fibrosis, angiogenesis, and the survival and growth of cardiomyocytes. Although use of EVs has gathered momentum in the cardiac field, several obstacles in both upstream and downstream processes during EV manufacture need to be addressed before clinical success can be achieved. Low EV yields obtained in small-scale cultures deter clinical translation, as mass production is a prerequisite to meet therapeutic doses. Moreover, standardizing EV manufacture is critical given the inherent heterogeneity of EVs and the constraints of current isolation techniques. In this review, we discuss the critical steps for the large-scale manufacturing of high-potency EVs for cardiac therapies. [ABSTRACT FROM AUTHOR]

Abstract Background Itaconic acid is a promising bio-based building block for the synthesis of polymers, plastics, fibers and other materials. In recent years, Ustilago cynodontis has emerged as an additional itaconate producing non-conventional yeast, mainly due to its high acid tolerance, which significantly reduces saline waste coproduction during fermentation and downstream processing. As a result, this could likely improve the economic viability of the itaconic acid production process with Ustilaginaceae. Results In this study, we characterized a previously engineered itaconate hyper-producing Ustilago cynodontis strain in controlled fed-batch fermentations to determine the minimal and optimal pH for itaconate production. Under optimal fermentation conditions, the hyper-producing strain can achieve the theoretical maximal itaconate yield during the production phase in a fermentation at pH 3.6, but at the expense of considerable base addition. Base consumption is strongly reduced at the pH of 2.8, but at cost of production yield, titer, and rate. A techno-economic analysis based on the entire process demonstrated that savings due to an additional decrease in pH control reagents and saline waste costs cannot compensate the yield loss observed at the highly acidic pH value 2.8. Conclusions Overall, this work provides novel data regarding the balancing of yield, titer, and rate in the context of pH, thereby contributing to a better understanding of the itaconic acid production process with Ustilago cynodontis, especially from an economic perspective.

Abstract Background Plastic is widely utilized in packaging, frameworks, and as coverings material. Its overconsumption and slow degradation, pose threats to ecosystems due to its toxic effects. While polyhydroxyalkanoates (PHA) offer a sustainable alternative to petroleum-based plastics, their production costs present significant obstacles to global adoption. On the other side, a multitude of household and industrial activities generate substantial volumes of wastewater containing both organic and inorganic contaminants. This not only poses a threat to ecosystems but also presents opportunities to get benefits from the circular economy. Main body of abstract Production of bioplastics may be improved by using the nutrients and minerals in wastewater as a feedstock for microbial fermentation. Strategies like feast-famine culture, mixed-consortia culture, and integrated processes have been developed for PHA production from highly polluted wastewater with high organic loads. Various process parameters like organic loading rate, organic content (volatile fatty acids), dissolved oxygen, operating pH, and temperature also have critical roles in PHA accumulation in microbial biomass. Research advances are also going on in downstream and recovery of PHA utilizing a combination of physical and chemical (halogenated solvents, surfactants, green solvents) methods. This review highlights recent developments in upcycling wastewater resources into PHA, encompassing various production strategies, downstream processing methodologies, and techno-economic analyses. Short conclusion Organic carbon and nitrogen present in wastewater offer a promising, cost-effective source for producing bioplastic. Previous attempts have focused on enhancing productivity through optimizing culture systems and growth conditions. However, despite technological progress, significant challenges persist, such as low productivity, intricate downstream processing, scalability issues, and the properties of resulting PHA. Graphical abstract

High throughput process development (HTPD) is established for time‐ and resource‐ efficient chromatographic process development. However, integration with non‐chromatographic operations within a monoclonal antibody (mAb) purification train is less developed. An area of importance is the development of low pH viral inactivation (VI) that follows protein A chromatography. However, the lack of pH measurement devices at the micro‐scale represents a barrier to implementation, which prevents integration with the surrounding unit operations, limiting overall process knowledge. This study is based upon the design and testing of a HTPD platform for integration of the protein A and low pH VI operations. This was achieved by using a design and simulation software before execution on an automated liquid handler. The operations were successfully translated to the micro‐scale, as assessed by analysis of recoveries and molecular weight content. The integrated platform was then used as a tool to assess the effect of pH on HMWC during low pH hold. The laboratory‐scale and micro‐scale elution pools showed comparable HMWC across the pH range 3.2–3.7. The investigative power of the platform is highlighted by evaluating the resources required to conduct a hypothetical experiment. This results in lower resource demands and increased labor efficiency relative to the laboratory‐scale. For example, the experiment can be conducted in 7 h, compared to 105 h, translating to labor hours, 3 h and 28 h for the micro‐scale and laboratory‐scale, respectively. This presents the opportunity for further integration beyond chromatographic operations within the purification sequence, to establish a fit‐to‐platform assessment tool for mAb process development. [ABSTRACT FROM AUTHOR]

The demand for Lentiviral Vector (LV) drug substance is increasing. However, primary capture using convective anion‐exchange chromatography remains a significant manufacturing challenge. This stems from a poor understanding of the complex adsorption behaviors linked to LVs intricate and variable structure, such as high binding heterogeneity which is typically characterized by a gradient elution profile consisting of two peaks. Understanding which LV structural components drive these phenomena is therefore crucial for rational process design. This work identifies the key LV envelope components responsible for binding to quaternary‐amine membrane adsorbents. Eliminating the pseudotype protein (Vesicular Stomatitis Virus G glycoprotein [VSV‐G]) did not impact the heterogenous two‐peak elution profile, suggesting it is not a major binding species. Digestion of envelope glycosaminoglycans (GAGs), present on proteoglycans, leads to a dramatic reduction in the proportion of vector eluted in peak 2, decreasing from 50% to 3.1%, and a threefold increase in peak 1 maximum. Data from reinjection experiments point towards interparticle envelope heterogeneity from discrete LV populations, where the two‐peak profile emerges from a subpopulation of LVs interacting via highly charged GAGs (peak 2) along with a weaker binding population likely interacting through the phospholipid membrane and envelope protein (peak 1). [ABSTRACT FROM AUTHOR]

Even though industrial biotechnology is successfully used for the production of some chemicals, for many other chemicals it is not yet competitive with conventional petrochemical production. Usually, fermentation as well as downstream processing requires improvement. Downstream processing has to deal with low product concentrations, microorganisms, impurities and thermodynamic constraints (e.g., azeotropes), which often makes it very challenging and expensive, especially on a large scale. However, downstream processing of biochemicals has not attracted as much attention as upstream fermentation processes. In that context, this perspective paper offers a lightly referenced scholarly opinion about the downstream processing performance of different bioalcohols after fermentation. Due to the stronger toxicity effects on microbes, the achievable concentrations of monohydric aliphatic alcohols in the fermentation broth decrease with the increasing chain length. Specifically, the concentrations used here are 6.14, 5.00, 1.61 and 0.24 wt% of ethanol, isopropanol, isobutanol and hexanol, respectively. More dilute fermentation broths lead to more complex recovery processes. According to our previous work, the total purification costs increase from 0.080 USD kg−1 for ethanol, 0.109 USD kg−1 for isopropanol and 0.161 USD kg−1 for isobutanol to 0.529 USD kg−1 for hexanol. A similar trend is noticeable for the energy usage (0.960, 1.348, 2.018 and 3.069 kWthh kg−1, respectively) and the related CO2 emissions (0.164, 0.221, 0.449 and 0.555 kgCO2 kg−1, respectively). This work shows that advanced separation and purification based on process intensification principles are crucial for overall efficient production processes. The achievable product concentration in the fermentation broth – and not so much the alcohol chain length – has the biggest influence on the performance of downstream processing. Therefore, simultaneous development of both upstream and downstream processing is necessary to ensure the competitiveness and viability of industrial fermentation processes. © 2024 The Author(s). Journal of Chemical Technology and Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry (SCI). [ABSTRACT FROM AUTHOR]

PDO (1,3-propanediol) is a platform chemical that is obtained by petrochemical routes and by fermentation. The latter needs relatively complex downstream processing after fermentation, due to the modest concentration of the high-boiling product, and the presence of microorganisms and many impurities in the fermentation medium. This novel research proposes an original large-scale (production capacity of 23 – 32 ktonne/y) process for the final purification of PDO and dominant by-products, from the fermentation of glucose or glycerol. Following the initial microfiltration, diafiltration, ultrafiltration and ion exchange steps, heat pump-assisted vacuum distillation was implemented to remove most of the water from the broth. Afterwards, an advanced highly-integrated dividing-wall column was designed to allow the final purification of PDO (product purity > 99.9 wt%) from light and heavy by-products. Fermentation by-products that are present in significant amounts can also be recovered and valorized. Overall, the developed final purification processes demonstrate cost-effectiveness (0.150 – 0.274 $/kg) and energy-efficiency (1.258 – 3.175 kW th h/kg) which contributes to the competitiveness of the overall downstream processing (0.256 – 0.384 $/kg and 1.487 – 3.496 kW th h/kg). [Display omitted] • Eco-efficient and fermentation-adjustable downstream processing of 1,3-propanediol • PDO and by-products can all be recovered at high purity and valorized accordingly • Low energy intensity (1.25–3.17 kW th h/kg) and cost-effective process (0.15–0.27 $/kg) • Competitive overall downstream processing (0.25–0.38 $/kg; 1.48–3.49 kW th h/kg) [ABSTRACT FROM AUTHOR]

In recent years, microalgal protein (MP) has gained a lot of interest, and research on its properties and applications is steadily increasing. However, the crude protein derived from microalgae is generally undervalued and has not yet found significant applications in the food industry. There are still many issues that need to be addressed in order to promote the MP industry and make it viable. In this review, about 30 microalgal species commonly used for human consumption are depicted with their safety aspects, and the potential MP production strategies and technologies are evaluated and compared in terms of protein yield efficiency. The latest findings on the nutritional, biological, and techno-functional properties of MP are summarized to identify the potential future applications in food. Apart from that, the challenges and current issues facing the MP industry are addressed, and several technological and strategic approaches are suggested to stimulate more relevant and problem-solving research activities in this area. From the literature review, it can be concluded that MPs have balanced amino acid profiles, high quality, and good bioaccessibility. They also possess various biological activities and diverse physicochemical properties, which could be suitable for different food development needs. However, the disruption of stubborn cell walls and the migration of low sensory scores of microalgae are important challenges for the current MP industry. To increase the sustainability of MP in the human food industry, developing low-cost and large-scale microalgae cultivation strategies, seeking efficient protein purification techniques, and exploring novel applications based on the MP properties are crucial. [ABSTRACT FROM AUTHOR]

The escalating worldwide concerns over the difficult degradation and pollution of plastic and its associated environmental and health risks have amplified the urgent need to develop biodegradable alternatives to traditional plastics. Polyhydroxyalkanoates (PHAs) have emerged as a promising class of biopolymers that offer a sustainable solution. Their commercial success in various applications has highlighted PHAs' potential to mitigate environmental impact. Critical to the economic feasibility of PHA production is the optimization of downstream processing methods, crucial for scaling operations from pilot to industrial scales. This paper reviews two decades of pilot-scale studies on PHA extraction, emphasizing the advancements and challenges encountered. It also discusses chemical extraction methods applied across different feedstock and microbial strains, highlighting their role in enhancing efficiency and sustainability. This comprehensive review underscores the imperative for advancing PHA technologies, particularly in refining extraction techniques, to facilitate broader adoption in industries seeking environmentally friendly alternatives to conventional plastics. [ABSTRACT FROM AUTHOR]

Background: Plastic is widely utilized in packaging, frameworks, and as coverings material. Its overconsumption and slow degradation, pose threats to ecosystems due to its toxic effects. While polyhydroxyalkanoates (PHA) offer a sustainable alternative to petroleum-based plastics, their production costs present significant obstacles to global adoption. On the other side, a multitude of household and industrial activities generate substantial volumes of wastewater containing both organic and inorganic contaminants. This not only poses a threat to ecosystems but also presents opportunities to get benefits from the circular economy. Production of bioplastics may be improved by using the nutrients and minerals in wastewater as a feedstock for microbial fermentation. Strategies like feast-famine culture, mixed-consortia culture, and integrated processes have been developed for PHA production from highly polluted wastewater with high organic loads. Various process parameters like organic loading rate, organic content (volatile fatty acids), dissolved oxygen, operating pH, and temperature also have critical roles in PHA accumulation in microbial biomass. Research advances are also going on in downstream and recovery of PHA utilizing a combination of physical and chemical (halogenated solvents, surfactants, green solvents) methods. This review highlights recent developments in upcycling wastewater resources into PHA, encompassing various production strategies, downstream processing methodologies, and techno-economic analyses. Short conclusion: Organic carbon and nitrogen present in wastewater offer a promising, cost-effective source for producing bioplastic. Previous attempts have focused on enhancing productivity through optimizing culture systems and growth conditions. However, despite technological progress, significant challenges persist, such as low productivity, intricate downstream processing, scalability issues, and the properties of resulting PHA. [ABSTRACT FROM AUTHOR]

Concerns about climate change and the reliance on fossil fuel reserves have motivated researchers to identify new renewable sources of energy. Biomass holds the potential to replace fossil‐derived products with biofuels and bio‐based chemicals. Plant‐derived lipids are promising sources of biofuels; however, the production of plant oil often leads to the release of massive amounts of carbon dioxide due to deforestation and land‐use change. The production of biofuels via plant oils (such as soybean) also competes with food production and in turn, impacts biodiversity. To mitigate these issues, the production of lipids from oleaginous yeasts could be an excellent alternative by incorporating these microbes into biorefineries utilizing agricultural or forest residues. Eventually, these microbial lipids could be potential sources for producing lipid‐derived biofuels. However, the current conventional methods for the production and recovery of lipids from oleaginous microbes suffer from economic and ecological challenges that affect its industrial‐scale expansion. This review highlights the major economic and environmental bottlenecks for the production of lipid‐derived biofuels from oleaginous yeasts. It also provides perspectives on the strategies that could be adapted on economic and ecological fronts to assist the expansion of the production of microbial lipid‐derived biofuels at an industrial scale. [ABSTRACT FROM AUTHOR]

Eco-friendly, biodegradable, microbially produced surfactants, known as biosurfactants, have been intensively studied for their ability as potential substitutes for their synthetic counterparts. Currently, the commercialization of biosurfactants compared to synthetic (chemical) surfactants remains an economic challenge due to high production costs and lower yields. This review details the challenges and better strategies for industrial scale-up of biosurfactant production and downstream processing techniques. An analysis of the use of low cost, renewable substrates, parameter optimization, strain improvement, bioreactor engineering is discussed. The role of various engineering factors that help in scale-up of biosurfactant production such as drag coefficient, Reynolds number, Enrichment ratio, Eӧtvӧs number have also been considered in this review article. The review article demonstrates the potential activity of integrated separation processes and applications of biosurfactants, bringing biosurfactants into mainstream commercialization. [ABSTRACT FROM AUTHOR]

Biopharmaceutical manufacture is transitioning from batch to integrated and continuous biomanufacturing (ICB). The common framework for most ICB, potentially enables a global biomanufacturing ecosystem utilizing modular and multi‐function manufacturing equipment. Integrating unit operation hardware and software from multiple suppliers, complex supply chains enabled by multiple customized single‐use flow paths, and large volume buffer production/storage make this ICB vision difficult to achieve with commercially available manufacturing equipment. Thus, we developed SymphonX™, a downstream processing skid with advanced buffer management capabilities, a single disposable generic flow path design that provides plug‐and‐play flexibility across all downstream unit operations and a single interface to reduce operational risk. Designed for multi‐product and multi‐process cGMP facilities, SymphonX™ can perform stand‐alone batch processing or ICB. This study utilized an Apollo™ X CHO‐DG44 mAb‐expressing cell line in a steady‐state perfusion bioreactor, harvesting product continuously with a cell retention device and connected SymphonX™ purification skids. The downstream process used the same chemistry (resins, buffer composition, membrane composition) as our historical batch processing platform, with SymphonX™ in‐line conditioning and buffer concentrates. We used surge vessels between unit operations, single‐column chromatography (protein A, cation and anion exchange) and two‐tank batch virus inactivation. After the first polishing step (cation exchange), we continuously pooled product for 6 days. These 6 day pools were processed in batch‐mode from anion exchange to bulk drug substance. This manufacturing scale proof‐of‐concept ICB produced 0.54 kg/day of drug substance with consistent product quality attributes and demonstrated successful bioburden control for unit‐operations undergoing continuous operation. [ABSTRACT FROM AUTHOR]

There is a strong interest in itaconic acid in the medical and pharmaceutical sectors, both as an anti-bacterial compound and as an immunoregulator in mammalian macrophages. Fungal hosts also produce itaconic acid, and in addition they can produce two derivatives 2-hydroxyparaconic and itatartaric acid. Not much is known about these two derivatives, while their structural analogy to itaconate could open up several applications. In this study, we report the production of these two itaconate-derived compounds. By overexpressing the itaconate P450 monooxygenase Cyp3 in a previously engineered itaconate-overproducing Ustilago cynodontis strain, itaconate was converted to its lactone 2-hydroxyparaconate. The second product itatartarate is most likely the result of the subsequent lactone hydrolysis. A major challenge in the production of 2-hydroxyparaconate and itatartarate is their co-production with itaconate, leading to difficulties in their purification. Achieving high derivatives specificity was therefore the paramount objective. Different strategies were evaluated including process parameters such as substrate and pH, as well as strain engineering focusing on Cyp3 expression and product export. 2-hydroxyparaconate and itatartarate were successfully produced from glucose and glycerol, with the latter resulting in a higher derivatives specificity due to an overall slower metabolism on this non-preferred carbon source. The derivatives specificity could be further increased by metabolic engineering approaches including the exchange of the native itaconate transporter Itp1 with the Aspergillus terreus itaconate transporter MfsA. Both 2-hydroxyparaconate and itatartarate were recovered from fermentation supernatants following a pre-existing protocol. 2-hydroxyparaconate was recovered first through a process of evaporation, lactonization, and extraction with ethyl acetate. Subsequently, itatartarate could be obtained in the form of its sodium salt by saponification of the purified 2-hydroxyparaconate. Finally, several analytical methods were used to characterize the resulting products and their structures were confirmed by nuclear magnetic resonance spectroscopy. This work provides a promising foundation for obtaining 2-hydroxyparaconate and itatartarate in high purity and quantity. This will allow to unravel the full spectrum of potential applications of these novel compounds.

The total cost of buffer preparation was analyzed for an existing single-use mAbs downstream processing facility. The cost effectiveness of outsourcing the liquid buffer as a ready-to-use and/or concentrate was examined by comparing a traditional made-in-house buffer from solid ingredients. The analysis show the combination of made-in-house buffer and concentrate buffer provides the greatest cost advantages. Ready-to-use buffers are more effective for improved facility footprint and provide cost benefits when in-house labor and consumables exceeds the cost of outsourcing. From the calculation of the cost of labor and number of pallets, although the difference in labor costs was small between the various buffer preparation methods, the use of concentrated buffers reduced both the total number of pallets and overall costs. When a new in-line dilution system is installed, a high facility utilization rate of at least ten preparations per year is required to leverage the cost savings from single-use consumables.

Abstract Succinic acid (SA) is one of the top platform chemicals with huge applications in diverse sectors. The presence of two carboxylic acid groups on the terminal carbon atoms makes SA a highly functional molecule that can be derivatized into a wide range of products. The biological route for SA production is a cleaner, greener, and promising technological option with huge potential to sequester the potent greenhouse gas, carbon dioxide. The recycling of renewable carbon of biomass (an indirect form of CO2), along with fixing CO2 in the form of SA, offers a carbon-negative SA manufacturing route to reduce atmospheric CO2 load. These attractive attributes compel a paradigm shift from fossil-based to microbial SA manufacturing, as evidenced by several commercial-scale bio-SA production in the last decade. The current review article scrutinizes the existing knowledge and covers SA production by the most efficient SA producers, including several bacteria and yeast strains. The review starts with the biochemistry of the major pathways accumulating SA as an end product. It discusses the SA production from a variety of pure and crude renewable sources by native as well as engineered strains with details of pathway/metabolic, evolutionary, and process engineering approaches for enhancing TYP (titer, yield, and productivity) metrics. The review is then extended to recent progress on separation technologies to recover SA from fermentation broth. Thereafter, SA derivatization opportunities via chemo-catalysis are discussed for various high-value products, which are only a few steps away. The last two sections are devoted to the current scenario of industrial production of bio-SA and associated challenges, along with the author's perspective.

Current downstream processing of monoclonal antibodies (mAbs) is limited in throughput and requires harsh pH conditions for mAb elution from Protein A affinity ligands. The use of an engineered calcium-dependent ligand (ZCa) in magnetic separation applications promises improvements due to mild elution conditions, fast processability, and process integration prospects. In this work, we synthesized and evaluated three magnetic nanoparticle types immobilized with the cysteine-tagged ligand ZCa-cys. Ligand homodimers were physically immobilized onto bare iron oxide nanoparticles (MNP) and MNP coated with tetraethyl orthosilicate (MNP@TEOS). In contrast, ZCa-cys was covalently and more site-directedly immobilized onto MNP coated with (3-glycidyloxypropyl)trimethoxysilane (MNP@GPTMS) via a preferential cysteine-mediated epoxy ring opening reaction. Both coated MNP showed suitable characteristics, with MNP@TEOS@ZCa-cys demonstrating larger immunoglobulin G (IgG) capacity (196 mg g−1) and the GPTMS-coated particles showing faster magnetic attraction and higher IgG recovery (88 %). The particles pave the way for the development of calcium-dependent magnetic separation processes.

The increasing applications for eicosapentaenoic acid (EPA) and the potential shortfall in supply due to sustainability and contamination issues related with its conventional sources (i.e., fish oils; seafood) led to an extensive search for alternative and sustainable sources, as well as production processes. The present mini-review covers all the steps involved in the production of EPA from microorganisms, with a deeper focus on microalgae. From production systems to downstream processing, the most important achievements within each area are briefly highlighted. Comparative tables of methodologies are also provided, as well as additional references of recent reviews, so that readers may deepen their knowledge in the different issues addressed. Key points: • Microorganisms are more sustainable alternative sources of EPA than fish. • Due to the costly separation from DHA, species that produce only EPA are preferable. • EPA production can be optimised using non-genetic and genetic tailoring engineering. [ABSTRACT FROM AUTHOR]

Polyhydroxyalkanoates (PHAs) have gained interest recently due to their biodegradability and versatility. In particular, the chemical compositions of medium‐chain‐length (mcl)‐PHAs are highly diverse, comprising different monomers containing 6–14 carbon atoms. This review summarizes different feedstocks and fermentation strategies to enhance mcl‐PHA production and briefly discusses the downstream processing. This review also provides comprehensive details on analytical tools for determining the composition and properties of mcl‐PHA. Moreover, this study provides novel information by statistically analyzing the data collected from several reports on mcl‐PHA to determine the optimal fermentation parameters (specific growth rate, PHA productivity, and PHA yield from various structurally related and unrelated substrates), mcl‐PHA composition, molecular weight (MW), and thermal and mechanical properties, in addition to other relevant statistical values. The analysis revealed that the median PHA productivity observed in the fed‐batch feeding strategy was 0.4 g L−1 h−1, which is eight times higher than that obtained from batch feeding (0.05 g L−1 h−1). Furthermore, 3‐hydroxyoctanoate and ‐decanoate were the primary monomers incorporated into mcl‐PHA. The investigation also determined the median glass transition temperature (−43°C) and melting temperature (47°C), which indicated that mcl‐PHA is a flexible amorphous polymer at room temperature with a median MW of 104 kDa. However, information on the monomer composition or heterogeneity and the associated physical and mechanical data of mcl‐PHAs is inadequate. Based on their mechanical values, the mcl‐PHAs can be classified as semi‐crystalline polymers (median crystallinity 23%) with rubber‐like properties and a median elongation at break of 385%. However, due to the limited mechanical data available for mcl‐PHAs with known monomer composition, identifying suitable processing tools and applications to develop mcl‐PHAs further is challenging. [ABSTRACT FROM AUTHOR]

Regulatory authorities recommend using residence time distribution (RTD) to address material traceability in continuous manufacturing. Continuous virus filtration is an essential but poorly understood step in biologics manufacturing in respect to fluid dynamics and scale‐up. Here we describe a model that considers nonideal mixing and film resistance for RTD prediction in continuous virus filtration, and its experimental validation using the inert tracer NaNO3. The model was successfully calibrated through pulse injection experiments, yielding good agreement between model prediction and experiment (R2> ${R}^{2}\gt $ 0.90). The model enabled the prediction of RTD with variations—for example, in injection volumes, flow rates, tracer concentrations, and filter surface areas—and was validated using stepwise experiments and combined stepwise and pulse injection experiments. All validation experiments achieved R2> ${R}^{2}\gt $ 0.97. Notably, if the process includes a porous material—such as a porous chromatography material, ultrafilter, or virus filter—it must be considered whether the molecule size affects the RTD, as tracers with different sizes may penetrate the pore space differently. Calibration of the model with NaNO3 enabled extrapolation to RTD of recombinant antibodies, which will promote significant savings in antibody consumption. This RTD model is ready for further application in end‐to‐end integrated continuous downstream processes, such as addressing material traceability during continuous virus filtration processes. [ABSTRACT FROM AUTHOR]

Succinic acid (SA) is one of the top platform chemicals with huge applications in diverse sectors. The presence of two carboxylic acid groups on the terminal carbon atoms makes SA a highly functional molecule that can be derivatized into a wide range of products. The biological route for SA production is a cleaner, greener, and promising technological option with huge potential to sequester the potent greenhouse gas, carbon dioxide. The recycling of renewable carbon of biomass (an indirect form of CO2), along with fixing CO2 in the form of SA, offers a carbon-negative SA manufacturing route to reduce atmospheric CO2 load. These attractive attributes compel a paradigm shift from fossil-based to microbial SA manufacturing, as evidenced by several commercial-scale bio-SA production in the last decade. The current review article scrutinizes the existing knowledge and covers SA production by the most efficient SA producers, including several bacteria and yeast strains. The review starts with the biochemistry of the major pathways accumulating SA as an end product. It discusses the SA production from a variety of pure and crude renewable sources by native as well as engineered strains with details of pathway/metabolic, evolutionary, and process engineering approaches for enhancing TYP (titer, yield, and productivity) metrics. The review is then extended to recent progress on separation technologies to recover SA from fermentation broth. Thereafter, SA derivatization opportunities via chemo-catalysis are discussed for various high-value products, which are only a few steps away. The last two sections are devoted to the current scenario of industrial production of bio-SA and associated challenges, along with the author's perspective. [ABSTRACT FROM AUTHOR]

The food insecurity due to a vertical increase in the global population urgently demands substantial advancements in the agricultural sector and to identify sustainable affordable sources of nutrition, particularly proteins. Single-cell protein (SCP) has been revealed as the dried biomass of microorganisms such as algae, yeast, and bacteria cultivated in a controlled environment. Production of SCP is a promising alternative to conventional protein sources like soy and meat, due to quicker production, minimal land requirement, and flexibility to various climatic conditions. In addition to protein production, it also contributes to waste management by converting it into food and feed for both human and animal consumption. This article provides an overview of SCP production, including its benefits, safety, acceptability, and cost, as well as limitations that constrains its maximum use. Furthermore, this review criticizes the downstream processing of SCP, encompassing cell wall disruption, removal of nucleic acid, harvesting of biomass, drying, packaging, storage, and transportation. The potential applications of SCP, such as in food and feed as well as in the production of bioplastics, emulsifiers, and as flavoring agents for baked food, soup, and salad, are also discussed. [ABSTRACT FROM AUTHOR]

Streptococcus pneumoniae can cause diseases with high mortality and morbidity. The licensed vaccines are based on capsular polysaccharides and induce antibodies with low cross reactivity, leading to restricted coverage of serotypes. For surpassing this limitation, new pneumococcal vaccines are needed for induction of broader protection. One important candidate is the pneumococcal surface protein A (PspA), which can be classified in 6 clades and 3 families. We have reported an efficient process for production and purification of untagged recombinant PspA from clade 4 (PspA4Pro). We now aim to obtain a highly pure recombinant PspA from clade 1 (PspA1) to be included, together with PspA4Pro, in a vaccine formulation to broaden response against pneumococci. The vector pET28a-pspA1 was constructed and used to transform Escherichia coli BL21(DE3) strain. One clone with high production of PspA1 was selected and adapted to high-density fermentation (HDF) medium. After biomass production in 6 L HDF using a bioreactor, the purification was defined after testing 3 protocols. During the batch bioreactor cultivation, plasmid stability remained above 90% and acetate formation was not detected. The final protein purification process included treatment with a cationic detergent after lysis, anion exchange chromatography, cryoprecipitation, cation exchange chromatography, and multimodal chromatography. The final purification process showed PspA1 purity of 93% with low endotoxin content and an overall recovery above 20%. The novel established process can be easily scaled-up and proved to be efficient to obtain a highly pure untagged PspA1 for inclusion in vaccine formulations. Key points: • Purification strategy for recombinant PspA1 from Streptococcus pneumoniae • Downstream processing for untagged protein antigens, the case of PspA1 • Purification strategy for PspA variants relies on buried amino acids in their sequences [ABSTRACT FROM AUTHOR]

Plants can produce complex pharmaceutical and technical proteins. Spider silk proteins are one example of the latter and can be used, for example, as compounds for high-performance textiles or wound dressings. If genetically fused to elastin-like polypeptides (ELPs), the silk proteins can be reversibly precipitated from clarified plant extracts at moderate temperatures of ~ 30 °C together with salt concentrations > 1.5 M, which simplifies purification and thus reduces costs. However, the technologies developed around this mechanism rely on a repeated cycling between soluble and aggregated state to remove plant host cell impurities, which increase process time and buffer consumption. Additionally, ELPs are difficult to detect using conventional staining methods, which hinders the analysis of unit operation performance and process development. Here, we have first developed a surface plasmon resonance (SPR) spectroscopy-based assay to quantity ELP fusion proteins. Then we tested different filters to prepare clarified plant extract with > 50% recovery of spider silk ELP fusion proteins. Finally, we established a membrane-based purification method that does not require cycling between soluble and aggregated ELP state but operates similar to an ultrafiltration/diafiltration device. Using a data-driven design of experiments (DoE) approach to characterize the system of reversible ELP precipitation we found that membranes with pore sizes up to 1.2 µm and concentrations of 2–3 M sodium chloride facilitate step a recovery close to 100% and purities of > 90%. The system can thus be useful for the purification of ELP-tagged proteins produced in plants and other hosts. [ABSTRACT FROM AUTHOR]

Biorefinery approaches offer the potential to improve the economics of the microalgae industry by producing multiple products from a single source of biomass. Chromochloris zofingiensis shows great promise for biorefinery due to high biomass productivity and a diverse range of products including secondary carotenoids, predominantly astaxanthin; lipids such as TAGs; carbohydrates including starch; and proteins and essential amino acids. Whilst this species has been demonstrated to accumulate multiple products, the development of an integrated downstream process to obtain these is lacking. The objective of this review paper is to assess the research that has taken place and to identify the steps that must be taken to establish a biorefinery approach for C. zofingiensis. In particular, the reasons why C. zofingiensis is a promising species to target for biorefinery are discussed in terms of cellular structure, potential products, and means to accumulate desirable components via the alteration of culture conditions. Future advances and the challenges that lie ahead for successful biorefinery of this species are also reviewed along with potential solutions to address them. [ABSTRACT FROM AUTHOR]

Background: The multimodal chromatography resins, such as Capto adhere, are considered good candidates to be utilized in downstream processing due to their high capacity and selectivity; however, their multimodal interactions lead to an intricacy in the adsorption-desorption patterns and systematic characterization of conditions for process steps is necessary. Methods: Capto adhere, a strong ion exchanger with multimodal functionality, was used in this study for the final aim of recombinant hepatitis B surface antigen (rHBsAg) purification from Pichia pastoris (P. pastoris) industrial feedstock. Optimization of various parameters was done using the design of experiments (DOE) approach to determine the best binding and non-binding conditions. Results: Maximum rHBsAg binding on Capto adhere occurred in 20 mM sodium acetate, pH 4.5, and a binding capacity of about 0.75 mg/ml was achieved, which was much higher than rHBsAg binding capacity of other resins reported so far. In elution optimization investigations, it was revealed that 1 M arginine (buffered in 50 mM sodium phosphate, pH 6.5) was the most efficient eluting agent. The binding and elution optimal conditions were utilized for further purification of rHBsAg from P. pastoris industrial feedstock in bind-elute mode, and the recovery and purity of the obtained rHBsAg were about 60% and 100%, respectively. Following optimization in the flow-through purification mode, the target protein recovery was significantly increased (up to 97%) and the target protein purity of more than 95% was achievable. SEC-HPLC analysis showed that the obtained retention times for the purified rHBsAg were similar to those reported previously. Conclusions: These results suggest that Capto adhere under such optimized conditions can be considered as a good candidate for efficient purification of rHBsAg from P. pastoris industrial feedstock in downstream processing.

Abstract Concerns about climate change and the reliance on fossil fuel reserves have motivated researchers to identify new renewable sources of energy. Biomass holds the potential to replace fossil‐derived products with biofuels and bio‐based chemicals. Plant‐derived lipids are promising sources of biofuels; however, the production of plant oil often leads to the release of massive amounts of carbon dioxide due to deforestation and land‐use change. The production of biofuels via plant oils (such as soybean) also competes with food production and in turn, impacts biodiversity. To mitigate these issues, the production of lipids from oleaginous yeasts could be an excellent alternative by incorporating these microbes into biorefineries utilizing agricultural or forest residues. Eventually, these microbial lipids could be potential sources for producing lipid‐derived biofuels. However, the current conventional methods for the production and recovery of lipids from oleaginous microbes suffer from economic and ecological challenges that affect its industrial‐scale expansion. This review highlights the major economic and environmental bottlenecks for the production of lipid‐derived biofuels from oleaginous yeasts. It also provides perspectives on the strategies that could be adapted on economic and ecological fronts to assist the expansion of the production of microbial lipid‐derived biofuels at an industrial scale.

Currently, microalgae-derived lutein is gaining attention for its potential applications in cosmeceutical, nutraceutical, pharmaceutical, and food industries. Lutein is of commercial interest for a broad variety of health benefits: antioxidant activity, skin health improvement, reducing age-related macular degeneration, and the treatment of cancer. Microalgae are the fastest-growing lutein source, have the highest content in nature, and are a promising sustainable alternative to the current commercial source, marigold flowers. Microalgal cultivation has added environmental benefits over plants with higher carbon sequestration, reduced water footprint, and no pesticide use. To date, no industrial facility exists for the production of lutein from microalgae. This review outlines the existing technologies for bioprocessing of lutein at pilot scale (cultivation, harvesting, extraction, and purification). In addition, lutein encapsulation, a seldom discussed area, is explored in depth. In view of this knowledge, lutein could be anticipated as the next successful sustainable product from microalgae obtained at industrial scale for the circular economy. [ABSTRACT FROM AUTHOR]

Adeno-associated viruses (AAV) are currently predominant viral transfer tools for gene therapy, and efforts are being made to design faster and more efficient methods and technologies for their manufacturing. The early selection of high-performing filters is essential for developing an ultrafiltration and diafiltration (UF/DF) process, especially when feed material is scarce, and timelines are short. However, few methods and technologies exist to enable process optimization with multiple variations in a single run. In this study, we explored the potential of Ambr® Crossflow for high-throughput, automated screening of different membrane materials, pore sizes and different process conditions for the UF/DF step of AAV8. The best overall performance was obtained with a 100 kDa PES flat sheet cassette. The UF/DF process was further transferred to a larger scale to the Sartoflow® Smart Tangential Flow Filtration (TFF) system using a 100 kDa PES Sartocon® Slice 200 cassette and compared to a 100 kDa PES hollow fiber. Virus recovery, permeate flux and total protein removal values of the flat sheet cassette were similar to those achieved in small-scale devices, and higher than those of the hollow fiber, thus demonstrating similar performance at a larger process scale. The high-throughput, automated method described herein allowed to screen multiple materials and process parameters of a UF/DF process in a time- and resource-efficient way, making it a useful tool to accelerate early-stage downstream process development of AAV. [ABSTRACT FROM AUTHOR]

Microbial cell factories, renowned for their economic and environmental benefits, have emerged as a key trend in academic and industrial areas, particularly in the fermentation of natural compounds. Among these, plant-derived terpenes stand out as a significant class of bioactive natural products. The large-scale production of such terpenes, exemplified by artemisinic acid—a crucial precursor to artemisinin—is now feasible through microbial cell factories. In the fermentation of terpenes, two-phase fermentation technology has been widely applied due to its unique advantages. It facilitates in situ product extraction or adsorption, effectively mitigating the detrimental impact of product accumulation on microbial cells, thereby significantly bolstering the efficiency of microbial production of plant-derived terpenes. This paper reviews the latest developments in two-phase fermentation system applications, focusing on microbial fermentation of plant-derived terpenes. It also discusses the mechanisms influencing microbial biosynthesis of terpenes. Moreover, we introduce some new two-phase fermentation techniques, currently unexplored in terpene fermentation, with the aim of providing more thoughts and explorations on the future applications of two-phase fermentation technology. Lastly, we discuss several challenges in the industrial application of two-phase fermentation systems, especially in downstream processing. [ABSTRACT FROM AUTHOR]

BACKGROUND: Isopropanol and acetone production by syngas fermentation is a promising alternative to conventional fossil carbon‐dependent production. However, this alternative technology has not yet been scaled up to an industrial level owing to the relatively low product concentrations (about 5 wt% in total). This original research aims to develop cost‐effective and energy‐efficient processes for the recovery of isopropanol and acetone from highly dilute fermentation broth (>94 wt% water) for large‐scale production (about 100 ktIPA+AC y−1). RESULTS: Vacuum distillation and pass‐through distillation enhanced with heat pumps or multi‐effect distillation were efficiently coupled with regular atmospheric distillation and extractive distillation in several innovative intensified downstream processes. Over 99.2% of isopropanol and 100% of acetone were recovered as high‐purity end‐products (>99.8 wt%). Advanced heat pumping (mechanical vapor recompression) and heat integration techniques were implemented to decrease total annual costs (0.109–0.137 USD kgIPA+AC−1), reduce energy requirements (1.348–2.043 kWth h kgIPA+AC−1) and lower CO2 emissions (0.067–0.191 kgCO2 kgIPA+AC−1), resulting in highly competitive recovery processes. CONCLUSION: The proposed three novel isopropanol and acetone recovery processes from dilute broth significantly contribute to the expansion of sustainable industrial fermentation. Furthermore, this original research is the first one to develop novel pass‐through distillation technology for the complex isopropanol–acetone–water system. All the designed processes are highly economically competitive and environmentally viable. In addition to recovering efficiently both isopropanol and acetone, the designed downstream processes offer the possibility to enhance the fermentation process by recycling all the present microorganisms and reducing fresh‐water requirements. © 2023 The Authors. Journal of Chemical Technology and Biotechnology published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry (SCI). [ABSTRACT FROM AUTHOR]

Increasing concerns over environmental pollution, climate change and energy security are driving a necessary transition from fossil carbon sources to more sustainable alternatives. Due to lower environmental impact, biochemicals are rapidly gaining significance as a potential renewable solution, particularly of interest in Europe. In this context, process systems engineering (PSE) helps with the decision-making at multiple scales and levels, aiming for optimum use of (renewable) resources. Fermentation using waste biomass or industrial offgases is a promising way for the production of these products. However, due to the inhibitory effects or low substrate concentrations, relatively low product concentrations can be obtained. Consequently, significant improvements in downstream processing are needed to increase the competitiveness of the overall bioprocesses. This paper supports sustainable development by providing new PSE perspectives on the purification of volatile bioproducts from dilute fermentation broths. Since purification significantly contributes to the total cost of biochemical production processes (20%-40% of the total cost), enhancing this part may substantially improve the competitiveness of the overall bioprocesses. The highly advanced downstream process offers the possibility of recovering high-purity products while enhancing the fermentation step by continuously removing inhibitory products, and recycling microorganisms with most of the present water. Besides higher productivity, the upstream process can be greatly improved by avoiding loss of biomass, enabling closed-loop operation and decreasing the need for fresh water. Applying heat pumping, heat integration and other methods of process intensification (PI) can drastically reduce energy requirements and CO2 emissions. Additionally, the opportunity to use renewable electricity instead of conventional fossil energy presents a significant step toward (green) electrification and decarbonization of the chemical industry. [ABSTRACT FROM AUTHOR]

L-cysteine is a proteogenic amino acid with many applications in the pharmaceutical, food, animal feed, and cosmetic industries. Due to safety and environmental issues in extracting L-cysteine from animal hair and feathers, the fermentative production of L-cysteine offers an attractive alternative using renewable feedstocks. Strategies to improve microbial production hosts like Pantoea ananatis, Corynebacterium glutamicum, Pseudomonas sp., and Escherichia coli are summarized. Concerning the metabolic engineering strategies, the overexpression of feedback inhibition-insensitive L-serine O-acetyltransferase and weakening the degradation of L-cysteine through the removal of L-cysteine desulfhydrases are crucial adjustments. The overexpression of L-cysteine exporters is vital to overcome the toxicity caused by intracellular accumulating L-cysteine. In addition, we compiled the process engineering aspects for the bioproduction of L-cysteine. Utilizing the energy-efficient sulfur assimilation pathway via thiosulfate, fermenting cheap carbon sources, designing scalable, fed-batch processes with individual feedings of carbon and sulfur sources, and implementing efficient purification techniques are essential for the fermentative production of L-cysteine on an industrial scale. [ABSTRACT FROM AUTHOR]

The development of biotransformation must integrate upstream and downstream processes. Upstream bioprocessing will influence downstream bioprocessing. It is essential to consider this because downstream processes can constitute the highest cost in bioprocessing. This review comprehensively overviews the most critical aspects of upstream and downstream bioprocessing in enzymatic biocatalysis. The main upstream processes discussed are enzyme production, enzyme immobilization methodologies, solvent selection, and statistical optimization methodologies. The main downstream processes reviewed in this work are biocatalyst recovery and product separation and purification. The correct selection and combination of upstream and downstream methodologies will allow the development of a sustainable and highly productive system. [ABSTRACT FROM AUTHOR]

Newcastle disease (ND) remains a critical disease affecting poultry in sub-Saharan Africa. In some countries, repeated outbreaks have a major impact on local economies and food security. Recently, we developed an adenovirus-vectored vaccine encoding the Fusion protein from an Ethiopian isolate of Newcastle disease virus (NDV). The adenoviral vector was designed, and a manufacturing process was developed in the context of the Livestock Vaccine Innovation Fund initiative funded by the International Development Research Centre (IDRC) of Canada. The industrially relevant recombinant vaccine technology platform is being transferred to the National Veterinary Institute (Ethiopia) for veterinary applications. Here, a manufacturing process using HEK293SF suspension cells cultured in stirred-tank bioreactors for the vaccine production is proposed. Taking into consideration supply chain limitations, options for serum-free media selection were evaluated. A streamlined downstream process including a filtration, an ultrafiltration, and a concentration step was developed. With high volumetric yields (infectious titers up to 5 × 109 TCID50/mL) in the culture supernatant, the final formulations were prepared at 1010 TCID50/mL, either in liquid or lyophilized forms. The liquid formulation was suitable and safe for mucosal vaccination and was stable for 1 week at 37 °C. Both the liquid and lyophilized formulations were stable after 6 months of storage at 4 °C. We demonstrate that the instillation of the adenoviral vector through the nasal cavity can confer protection to chickens against a lethal challenge with NDV. Overall, a manufacturing process for the adenovirus-vectored vaccine was developed, and protective doses were determined using a convenient route of delivery. Formulation and storage conditions were established, and quality control protocols were implemented. [ABSTRACT FROM AUTHOR]

In the quest for possibilities to valorize the dairy by-product acid whey, we developed a sequential process comprising filtration and magnetic separation to isolate the valuable protein lactoferrin thereof. In the first step, we clarified whey by microfiltration, followed by selective lactoferrin enrichment through ultrafiltration. This process raises the initially low lactoferrin concentration (

Abstract Polyhydroxyalkanoates (PHAs) have gained interest recently due to their biodegradability and versatility. In particular, the chemical compositions of medium‐chain‐length (mcl)‐PHAs are highly diverse, comprising different monomers containing 6–14 carbon atoms. This review summarizes different feedstocks and fermentation strategies to enhance mcl‐PHA production and briefly discusses the downstream processing. This review also provides comprehensive details on analytical tools for determining the composition and properties of mcl‐PHA. Moreover, this study provides novel information by statistically analyzing the data collected from several reports on mcl‐PHA to determine the optimal fermentation parameters (specific growth rate, PHA productivity, and PHA yield from various structurally related and unrelated substrates), mcl‐PHA composition, molecular weight (MW), and thermal and mechanical properties, in addition to other relevant statistical values. The analysis revealed that the median PHA productivity observed in the fed‐batch feeding strategy was 0.4 g L−1 h−1, which is eight times higher than that obtained from batch feeding (0.05 g L−1 h−1). Furthermore, 3‐hydroxyoctanoate and ‐decanoate were the primary monomers incorporated into mcl‐PHA. The investigation also determined the median glass transition temperature (−43°C) and melting temperature (47°C), which indicated that mcl‐PHA is a flexible amorphous polymer at room temperature with a median MW of 104 kDa. However, information on the monomer composition or heterogeneity and the associated physical and mechanical data of mcl‐PHAs is inadequate. Based on their mechanical values, the mcl‐PHAs can be classified as semi‐crystalline polymers (median crystallinity 23%) with rubber‐like properties and a median elongation at break of 385%. However, due to the limited mechanical data available for mcl‐PHAs with known monomer composition, identifying suitable processing tools and applications to develop mcl‐PHAs further is challenging.

Abstract Background Reducing the costs of biorefinery processes is a crucial step in replacing petrochemical products by sustainable, biotechnological alternatives. Substrate costs and downstream processing present large potential for improvement of cost efficiency. The implementation of in situ adsorption as an energy-efficient product recovery method can reduce costs in both areas. While selective product separation is possible at ambient conditions, yield-limiting effects, as for example product inhibition, can be reduced in an integrated process. Results An in situ adsorption process was integrated into the production of itaconic acid with Ustilago cynodontis IAmax, as an example of a promising biorefinery process. A suitable feed strategy was developed to enable efficient production and selective recovery of itaconic acid by maintaining optimal glucose concentrations. Online monitoring via Raman spectroscopy was implemented to enable a first process control and understand the interactions of metabolites with the adsorbent. In the final, integrated bioprocess, yield, titre, and space–time yield of the fermentation process were increased to values of 0.41 gIA/gGlucose, 126.5 gIA/L and 0.52 gIA/L/h. This corresponds to an increase of up to 30% in comparison to the first extended batch experiment without in situ product removal. Itaconic acid was recovered with a purity of at least 95% and high concentrations above 300 g/L in the eluate. Conclusion Integration of product separation via adsorption into the bioprocess was successfully conducted and improved the efficiency of itaconic acid production. Raman spectroscopy was proven to be a reliable tool for online monitoring of various metabolites and facilitated design and validation of the complex separation and feed process. The general process concept can be transferred to the production of various similar bioproducts, expanding the tool kit for design of innovative biorefinery processes.