Addressing temperature gradient challenge in scaling up solid-state fermentation : A strategy using thermophilic strains for biosurfactant production
Bueno Mancebo, José Antonio (Universitat Autònoma de Barcelona. Departament d'Enginyeria Química, Biològica i Ambiental)
Artola Casacuberta, Adriana (Universitat Autònoma de Barcelona. Departament d'Enginyeria Química, Biològica i Ambiental)
Farooq, Syeda Amna (Universitat Autònoma de Barcelona. Departament d'Enginyeria Química, Biològica i Ambiental)
Barrena Gómez, Raquel (Universitat Autònoma de Barcelona. Departament d'Enginyeria Química, Biològica i Ambiental)
Gea Leiva, Teresa (Universitat Autònoma de Barcelona. Departament d'Enginyeria Química, Biològica i Ambiental)

Date:	2026
Abstract:	Solid-state fermentation (SSF) is a promising approach for sustainable bioproduction production, particularly when using organic waste as a substrate. However, temperature gradients inherent to large-scale SSF often reduce process efficiency. This study developed a strategy for designing of a lipopeptide biosurfactant production process, scaling SSF in packed-bed bioreactors by thermophilic strains using winterisation oil cake (WOC) and sugarcane molasses (MOL) as nutrient sources. Fermentations at lab-scale (0. 5 L) and pilot-scale (50 L) demonstrated a robust and reproducible process despite temperature changes from microbial activity. Among the strains tested, Bacillus subtilis CBI-7S1 was the highest producer, with optimal substrates amounts of 24 g of WOC and 12 g of MOL, producing 24. 9 mg of crude lipopeptides per gram of dry matter (DM) at 0. 5 L scale. These conditions were reproduced at pilot scale, with concentrations from 12 to 24 mg g DM. Moisture content strongly influenced biosurfactant production, while oxygen consumption was a reliable monitoring parameter. Surface tension was evaluated under different pH, temperature, and salinity, and mass spectrometry identified surfactin, iturin, and fengycin congeners. These findings provide insights into overcoming temperature gradients during scale-up and show that thermophilic strains enable biosurfactant production under SSF at pilot scale. This approach enhances SSF technological maturity, supporting its broader use in sustainable production of targeted metabolites across diverse bioprocesses.
Grants:	Agencia Estatal de Investigación PID2023-146978OB-100 Agencia Estatal de Investigación PRE2021-097852
Note:	Altres ajuts: acords transformatius de la UAB
Rights:	Aquest document està subjecte a una llicència d'ús Creative Commons. Es permet la reproducció total o parcial, la distribució, i la comunicació pública de l'obra, sempre que no sigui amb finalitats comercials, i sempre que es reconegui l'autoria de l'obra original. No es permet la creació d'obres derivades.
Language:	Anglès
Document:	Article ; recerca ; Versió publicada
Subject:	Lipopeptide ; Bacillus subtilis ; Thermophiles ; Biosurfactants ; Biowaste
Published in:	Biochemical Engineering Journal, Vol. 227 (March 2026) , art. 110037, ISSN 1873-295X

DOI: 10.1016/j.bej.2025.110037

11 p, 4.0 MB

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Research literature > UAB research groups literature > Research Centres and Groups (research output) > Engineering > Composting Research Group (GICOM)
Articles > Research articles
Articles > Published articles