Key concepts and technologies used in industrial microbiology
Applications of industrial microbiology
Challenges and future outlook of industrial microbiology
References
Industrial microbiology is a branch of applied microbiology that uses microbes, such as bacteria, algae, and fungi, to produce high-value products, including drugs and fuels.1
This field of science offers endless opportunities that include the potential to replace harmful plastics with biodegradable ones, fossil fuels with biofuels, and highly polluting chemical processes with biocompatible alternatives.
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Key concepts and technologies used in industrial microbiology
The fundamental idea of industrial microbiology is dependent on the identification of microbes from natural sources for application in large-scale fermentative processes to produce metabolites of industrial interest.2
Typically, the isolated microbes are screened and characterized per specific selection criteria. The culture conditions, such as pH, temperature, nutrients, and oxygen levels, are optimized for increased production of the bioproducts.
Over the years, the advent and advancements in multiple scientific technologies have revolutionized the field of industrial microbiology. Some of the key areas are discussed below:
Synthetic biology and genetic engineering
Synthetic biology enables the creation of custom microbial strains and cell lines tailored for specific production processes.3 Genetic engineering is employed in synthetic biology to overcome the physiological limitations of microorganisms.
This technique focuses on enhancing productivity, reducing by-product formation, improving cell growth, and stabilizing biological systems. Ultimately, these microbes undergo fermentation in a bioreactor for the production of target products.
Bioreactors
Fermentation is the core of bioprocessing. In this process, microbes are cultured in a bioreactor under controlled conditions for a high yield of the target product.4 The bioreactor design and process are critical to optimal yield.
Real-time monitoring and regulating each step of the biomanufacturing process through process analytical technologies (PAT) and advanced control systems have ensured higher productivity and reduced variability of the final product.5
Advancements in bioreactor technology, such as the development of continuous fermentation systems and single-use bioreactors, have significantly improved high-scale bioprocessing efficiency.4
Unlike the traditional batch fermentation systems, the continuous fermentation systems operate in a steady state where nutrients are continuously added in the bioreactor and products are constantly harvested. The use of single-use bioreactors has reduced the risk of contamination and offers greater product safety.
Downstream processes
Following fermentation, the downstream process involves a series of steps to recover and purify the product from the fermentation broths or cells.
Centrifugation and filtration are common techniques used to isolate cells from the broth. Different chromatographic methods are used to test product purity. Depending on the nature of the final product, downstream processing techniques are selected.6
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Applications of industrial microbiology
Industrial microbiology plays an important role in a wide range of sectors, including pharmaceuticals, food and beverages, agriculture, biofuel, and environment management. Some of the major applications are discussed below:
Biopharmaceuticals: Biopharmaceutical products, such as vaccines, hormones, enzymes, and monoclonal antibodies, are produced via industrial microbiology techniques. These products are used for the treatment of many diseases, including infectious diseases, cancer, and diabetics.7
Biofuels and bioenergy: Industrial microbiology plays a crucial role in the production of biofuels, which can be used as an alternative to fossil fuels. Microbial fermentation enables the synthesis of biogas, biofuels, and biodiesel from renewable biomass sources.8
The production of cellulosic ethanol from agricultural residues and woody plants has ensured the sustainability and economic viability of biofuel production. Genetically engineered yeast and bacterial strains exhibited greater efficiency in converting biomass into biofuels (e.g., bioethanol).
Food and beverage: Industrial microbiology techniques produce enzymes, such as amylases and proteases, which are used in food industries, particularly baking and brewing. These enzymes improve the texture, flavor, and shelf life of the final product.9 Microbial fermentation techniques are widely used to develop probiotics and plant-based proteins.
Agriculture: Industrial microbiology has revolutionized the agricultural field by developing genetically engineered crops. For example, Bt corn and Bt cotton are genetically engineered crops that express a bacterial toxin that eliminates specific plant pests.10
Cultivation of these crops has efficiently reduced the use of chemical pesticides, prevented soil contamination, and improved crop yield.
Environmental management: Different microorganisms are used to tackle environmental challenges, including pollution and waste management.11 Microorganisms are used for the bioremediation process that involves the detoxification of degradation of pollutants in soil, air, and water.
Others: Industrial biotechnology is also applied in textile manufacturing processes, including bio-polishing and de-sizing, that enhance fabric quality. Bioplastics, such as polylactic acid (PLA) and polyhydroxyalkanoates (PHAs), which play a crucial role in alleviating plastic pollution, are manufactured through microbial fermentation.
Learn more about isolation techniques in microbiology
Challenges and future outlook of industrial microbiology
Despite tremendous advancements in the biomanufacturing process, several challenges and limitations need to be addressed to fully harness the potential of industrial biotechnology. These challenges concern technology, regulation, the economy, and the environment.
The development of genetically modified microbial strains and cell lines requires extensive genetic engineering and metabolic pathway optimization. These methods are complex and time-consuming. Researchers also experience many challenges in maintaining the stability of these strains under industrial conditions, which is critical for large-scale applications.
Since bioreactors, raw materials, and downstream processes are often highly expensive, small-scale industries encounter significant economic challenges to establish their product.
Industrial microbiology is not without environmental challenges. The spent microbial cultures and fermentation residues must be treated to avoid adverse effects to the environment, and these steps add to the manufacturing costs.
Regulatory agencies such as the US Food and Drug Administration have strict guidelines to ensure the safety of bioproducts. The pharmaceutical industry mandates rigorous documentation and quality control measures to comply with the rules of the global regulatory agencies. A minor change in the production process requires revalidation and approval.
In the future, bioreactor design and process control could be improved to increase the scalability and efficiency of bioprocessing. Furthermore, innovations in genetic engineering and synthetic biology could focus on the development of stable and efficient microbial strains and cell lines for large-scale production in a cost-efficient manner.
References
- Gholami-Shabani M, et al. Food Microbiology: Application of Microorganisms in Food Industry. IntechOpen. 2023; doi: 10.5772/intechopen.109729
- Olicón-Hernández DR, et al. Fundaments and Concepts on Screening of Microorganisms for Biotechnological Applications. Mini Review. Curr Microbiol. 2022;79(12):373. doi: 10.1007/s00284-022-03082-2.
- Yan X, et al. Applications of synthetic biology in medical and pharmaceutical fields. Signal Transduct Target Ther. 2023;8(1):199. doi: 10.1038/s41392-023-01440-5.
- Mitra S, Murthy GS. Bioreactor control systems in the biopharmaceutical industry: a critical perspective. Syst Microbiol Biomanuf. 2022;2(1):91-112. doi: 10.1007/s43393-021-00048-6.
- Maruthamuthu MK, et al. Process Analytical Technologies and Data Analytics for the Manufacture of Monoclonal Antibodies. Trends Biotechnol. 2020;38(10):1169-1186. doi: 10.1016/j.tibtech.2020.07.004.
- Antecka A, et al. Comparison of downstream processing methods in purification of highly active laccase. Bioprocess Biosyst Eng. 2019;42(10):1635-1645. doi: 10.1007/s00449-019-02160-3.
- Kesik-Brodacka M. Progress in biopharmaceutical development. Biotechnol Appl Biochem. 2018;65(3):306-322. doi: 10.1002/bab.1617.
- Love J. Microbial pathways for advanced biofuel production. Biochem Soc Trans. 2022;50(2):987-1001. doi: 10.1042/BST20210764.
- Raveendran S, et al. Applications of Microbial Enzymes in Food Industry. Food Technol Biotechnol. 2018;56(1):16-30. doi: 10.17113/ftb.56.01.18.5491.
- Abdul Aziz M, et al. Genetically engineered crops for sustainably enhanced food production systems. Front Plant Sci. 2022;13:1027828. doi: 10.3389/fpls.2022.1027828.
- Bala S, et al. Recent Strategies for Bioremediation of Emerging Pollutants: A Review for a Green and Sustainable Environment. Toxics. 2022;10(8):484. doi: 10.3390/toxics10080484.
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