Indian Journal of Biotechnology Vol. 5 (Suppl), July 2006, pp. 337-345 Production of a high maltose-forming, hyperthermostable and Ca2+independent amylopullulanase by an extreme thermophile Geobacillus thermoleovorans in submerged fermentation S M Noorwez, M Ezhilvannan and T Satyanarayana* Department of Microbiology, University of Delhi South Campus, New Delhi 110 021, India Production of a hyperthermostable, high maltose-forming and Ca2+-independent amylopullulanase by an extreme thermophile Geobacillus thermoleovorans was studied in submerged fermentation. Parametric optimization led to secretion of amylopullulanase (2850 U L-1 of α-amylase, 840 U L-1 of pullulanase) in a starch-yeast extract medium (2% starch, 0.1% ammonium sulphate, 0.3% yeast extract, 0.1% K2HPO4, 0.1% NaCl, 0.01% MgSO4.7H2O and 0.1% Maltose) using 2% inoculum (12 h) at 70°C and 200 rpm in 20 h. The addition of trace elements, detergents, surfactants and additives did not stimulate growth or enzyme production. The hydrolysis of pullulan and starch yielded maltotriose, and maltose, maltotriose and maltotetraose as the major end products, respectively. The cultivation of the organism in a laboratory fermenter showed (i) abolition of the lag phase, (ii) a 2-fold increase in enzyme production (5880 U L-1 of α-amylase, 1900 U L-1 of pullulanase) and (iii) a reduction in fermentation time to 7-8 h. Keywords: Geobacillus thermoleovorans, amylopullulanase, submerged fermentation, starch hydrolysis IPC Code: Int. Cl.8 C12N9/44; C12R1/01 Introduction The steep increase in the demand for enzymes as industrial catalysts has led to rapid developments in the enzyme industry. The starch processing industry is unique among industrial enzyme sectors, where application of thermostable enzymes is essential for the industry. The potential exploitation of sugars from natural sources is useful for (i) glucose/fructose syrup production, (ii) synthesis of non-fermentable carbohydrates, and (iii) anti-cariogenic and antistaling agents in baking1. Thermostable amylolytic enzymes of microbial origin are used extensively in food, chemical, detergent and textile industries, to convert starch into low molecular weight products. Of special interest are thermophilic microorganisms endowed with production of thermostable enzymes with remarkable properties2. A new class of amylolytic enzymes, amylopullulanases (Type-II pullulanases) has been reported in thermophilic bacteria and archaea with dual specificity for α-1,4- and α-1,6- glycosidic linkages in starch3,4. These enzymes have great potential for direct use in (i) starch liquefaction (with or without α-amylase), (ii) saccharification processes, ________________ *Author for correspondence: Tel.: 91-11-24112008; Fax: 91-11-2411 5270 E-mail: [email protected] and (iii) in baking. The need to look for highly thermostable and thermoactive pullulanases from thermophiles has been emphasized5. Pullulanases may prove superior to the commercial thermostable αamylase from B. licheniformis used for industrial starch liquefaction. Pullulanases may also be useful for one-step starch conversion into maltodextrins, and hence, suggested as an alternative to replace αamylases in starch liquefaction. Certain amylopullulanases produce maltose, maltotriose, and maltotetraose (DP2 to DP4) as the major end products of starch hydrolysis, and, therefore, suggested as catalysts in one-step liquefaction-saccharification process for the production of high DP2-DP4 syrups6. The baking industry is another large consumer of starch and starch-modifying enzymes. All undesirable changes (staling), viz. increase of crumb firmness, loss of crispness of the crust, decrease in moisture content of the crumb and loss of bread flavour usually occur upon storage. Staling limits the shelf-life of baked products, and hence, causes economic losses to baking industries. Amylolytic enzymes active on starch have been suggested as anti-staling agents. For this purpose, α-amylases were added during dough preparation to generate fermentable compounds and to improve the retention of softness of baked goods. However, slight overdose of α-amylase is not 338 INDIAN J BIOTECHNOL, JULY 2006 attractive due to the production of sticky bread. Alternatively, pullulanases are claimed to (i) alleviate sticky defect in bread, (ii) increase shelf-life, and (iii) loaf volume of baked goods7- 9. In order to develop novel processes, microbes endowed with thermostable enzymes are desired. For this, thermophilic microbes with the ability to produce thermostable enzymes having high operation stability and a longer shelf-life are warranted10. Very few investigations have emphasized on strain selection, their growth and enzyme yield optimization, even though the level of thermophilic enzyme production is relatively low11. Several thermophiles are known to produce Type-II pullulanase (amylopullulanase)12. Hence, this investigation has been attempted to throw light on the optimization of medium components and cultural parameters in submerged fermentation for amylopullulanase secretion by Geobacillus thermoleovorans. Materials and Methods Source of the Bacterial Strain The bacterial strain NP33 was isolated from a hot water spring of the Waimangu Volcanic Valley (New Zealand), and maintained as described earlier13, 14. The isolate producing relatively high Ca2+-independent amylopullulanase was identified as Geobacillus thermoleovorans by the analysis of partial 16S rDNA gene sequence [GenBank (Bethesda, Maryland, USA) accession no. AY427833]. The bacterial strain has been deposited at Microbial Type Culture and Collection & Gene Bank (MTCC), Institute of Microbial Technology, Chandigarh (India) with accession number MTCC 4219. Production of Amylopullulanase The enzyme was produced by cultivating the bacterium in 250 mL Erlenmeyer flasks containing 50 mL of the basal medium (g L-1: soluble starch, 10.0; yeast extract, 3.0; ammonium sulphate, 3.0; K2HPO4, 1.0; MgSO4.7H2O, 0.2; NaCl, 1.0 and pH 7.0), in an incubator shaker (New Brunswick Scientific Co. Inc., NJ, USA) at 70ºC for 20 h at 200 rev min-1. A 2 % cell suspension of G. thermoleovorans prepared from 10 h-old seed culture was used as inoculum. The culture fluid was centrifuged at 8000 xg for 20 min and 4ºC (Sorvall RC 5C Plus; Kendro Labs, Newtown, USA). The cell-free supernatant was used as the source of extracellular amylopullulanase. Enzyme Assays Both α-amylase and pullulanase activities were determined by measuring the amount of reducing sugars liberated from 1% soluble starch (Sigma) or 1% pullulan (Sigma) at 80°C according to Bernfeld15 using dinitrosalicylic acid (DNSA) reagent16. One international unit (IU) of α-amylase or pullulanase is defined as the amount of enzyme that liberates 1 μmol of reducing sugar as glucose min-1 mL-1 under the assay conditions. Parametric Optimization Each parameter was examined after taking into account the previously optimized condition i.e., ‘one variable at a time’ approach. All the experiments were performed in triplicate and the average values are presented. Amylopullulanase production was studied at regular intervals during 24 h. To study the effect of pH, the bacterial strain was cultivated in the basal medium buffered at different pH [0.1 M citrate buffer (pH 3.0-5.0), 0.1 M phosphate buffer (pH 6.0-8.0) and 0.1 M glycine-NaOH buffer (pH 9.0-10.0)]. The effects of temperature and agitation were assessed by cultivating the bacterial strain at different temperatures (45-80°C) in shake flasks and agitating in the ranges between 50 and 250 rev min-1. Inoculum was prepared from the cultures grown for varying time intervals (6-16 h), and was used at different levels (1-6 %) to study the effect of inoculum age and size on amylopullulanase secretion. The bacterial strain was also grown in the basal medium containing different carbon sources (1%) (glucose, maltose, galactose, sucrose, fructose, xylose, lactose, raffinose, glycerol, sorbitol, xylitol, maltodextrins, PEG, PVA, xylan and arabinogalactan) instead of starch to study their effect on the secretion of the enzyme. Three different starch sources (Merck soluble starch, corn starch and tapioca starch, 1% w/v) were incorporated in the production medium to select the best. Effects of various concentrations of soluble starch (0.5-4.0% w/v), and maltose (0.1-1.5% w/v) supplementation in 2% starch containing medium were also tested. Ammonium sulphate present in the basal medium was substituted with equimolar proportions of different nitrogen sources (ammonium sulphate, tryptone, peptone, casein, ammonium nitrate, urea, potassium nitrate, ammonium hydrogen phosphate, ammonium chloride and asparagines) to assess the effect of different organic and inorganic nitrogen sources on enzyme production. The effect of different levels of yeast extract (0.11.5% w/v), ammonium sulphate (0.1-1% w/v), NOORVEZ et al: AMYLOPULLULANASE PRODUCTION BY G. THERMOLEOVORANS 339 MgSO4.7H20 (0.01-0.10% w/v), K2HPO4 (0.05-0.15% w/v), NaCl (0.1-1.0% w/v) and various cations (0.01% w/v), additives (0.1% w/v) and detergents (0.1% w/v) were also studied on enzyme production. Batch Fermentation in a Lab Fermenter The bacterial strain was cultivated in 22 L Biostat C (B Braun Biotech International, Mersungen, Germany) fermenter containing 10 L of the amylopullulanase production medium (g L-1: soluble starch, 20.0; yeast extract, 3.0; ammonium sulphate, 1.0; K2HPO4, 1.0; MgSO4.7H2O, 0.1; maltose, 1.0; and NaCl, 1.0). The fermenter was operated at 65ºC, 200 rev min-1 and 1 vvm of aeration. The medium was inoculated with 2% of 12 h-old seed culture. The pH of the medium was maintained at 7.0 using sterile 1 M NaOH/HCl. The samples were withdrawn at regular intervals for determining amylopullulanase titres. Identification of End-Products of Starch and Pullulan hydrolysis The hydrolysis products of 1% starch and 1% pullulan by the action of amylopullulanase from G. thermoleovorans at 80°C were analyzed by TLC (Silica gel) plate 60 F (E Merck AG, Darmstadt, Germany) and HPLC using an Aminex-HPX-42A oligosaccharide column (300 by 78 mm; Bio-Rad, Hercules, California, USA)14,17. Results and Discussion The extremely thermophilic bacterium G. thermoleovorans secreted high titres of -1 amylopullulanase (210 U L α-amylase and 48 U L-1 pullulanase) in the basal medium within 20 h in shake flasks when the organism was cultivated at 70°C, 200 rpm, pH 7.0 with 2% of 12 h old inoculum (Fig. 1). The action of extracellular amylolytic enzyme of G. thermoleovorans on starch and pullulan liberated maltose, maltotriose and other oligosaccharides, and only maltotriose, respectively. Among different carbon sources tested, a nearly similar level of amylopullulanase was produced in starch, maltose, maltodextrin and glucose. Among the different starches, soluble starch (2%) supported a high enzyme production. A low maltose supplementation (0.1%) to 2% starch containing medium further enhanced enzyme titre (Fig. 2). A high enzyme production was recorded in organic nitrogen sources, tryptone and casein, and among inorganic nitrogen sources, ammonium sulphate and ammonium nitrate. The enzyme production was high Fig. 1—Effect of (A) fermentation time, (B) temperature, (C) pH, and (D) agitation on amylopullulanase production. at a low concentration of ammonium sulphate (0.1%), and thereafter, it declined sharply (Fig. 3). 340 INDIAN J BIOTECHNOL, JULY 2006 Fig. 2—Effect of (A) different carbon sources, (B) starch concentration and (C) maltose supplementation in 2% starch containing medium on amylopullulanase production. The amylopullulanase production was enhanced with an increase in the level of yeast extract upto 0.3 % and thereafter, it declined (Fig. 3). A low magnesium concentration (0.01 %) supported a good enzyme titre (α-amylase 3000 U, pullulanase 840 U L-1) and at higher levels, the enzyme secretion declined. The enzyme titre was high at 0.1% K2HPO4 (α-amylase 2200 U, pullulanase 950 U L-1) with a decline on either side of this concentration. Surfactants such as Tween-80 and SDS did not have any observable effect on enzyme production, Fig. 3—Effect of different concentrations of (A) nitrogen sources, (B) ammonium sulphate and (C) yeast extract on amylopullulanase production. while Triton X-100 lowered the production to about 50%. The presence of glycine also did not affect the enzyme secretion. Among the cations, cobalt enhanced enzyme production, but Cu2+ and Mn2+ strongly inhibited the enzyme secretion. However, iron and calcium did not exert any noticeable effect on the enzyme production (Table 1). When G. thermoleovorans was cultivated in a 22 L laboratory fermenter, the enzyme production levels [ NOORVEZ et al: AMYLOPULLULANASE PRODUCTION BY G. THERMOLEOVORANS markedly increased from 830 to 1900 and 2850 to 5880 U L-1 of pullulanase and α-amylase, respectively (Fig. 4). A peak in enzyme secretion was attained in 7-8 h in fermenter, in contrast to 20 h in the shake flasks, without any significant increase in biomass. The production of amylopullulanase was sustainable in flasks and enhanced in the fermenter (Tables 2 & 3). Novel starch- and pullulan-degrading enzymes are classified on the basis of the end-products of hydrolysis. Maltotriose was the exclusive product of pullulan hydrolysis by pullulanase action of amylopullulanase, while its α-amylase activity led to release of maltose, maltotriose and maltotetraose from Table 1—Effect of surfactants, detergents, additives and divalent ions on enzyme production Enzyme Production (U L-1)* Source α-amylase pullulanase 2924 3100 2920 2810 1560 2563 3252 2863 2657 2842 820 920 918 790 410 533 1098 798 556 810 Control SDS Glycine Tween-80 Triton X-100 Cu++ Co++ Fe++ Mn++ Ca++ 341 starch18,19. Thin layer chromatography and HPLC have been extensively used for the identification of enzyme reaction products20. As the enzyme of G. thermoleovorans hydrolyzed pullulan to maltotriose and starch to maltose, maltotriose and maltotetraose, it was classified as an amylopullulanase or Type II pullulanase. This is the first report on the secretion of amylopullulanase by G. thermoleovorans. The extracellular enzymes produced by various members of Bacillus and the related genera play a vital role in the biotechnology industry. Thermophiles in general are known to produce low amounts of biomass and also enzyme titres. Optimization of various cultural parameters was carried out to increase the yield of biomass, enzymes and other microbial products10,11. The production of enzyme in various media by G. thermoleovorans led to the selection of a rather simple medium that supported relatively high enzyme titres. The production of the enzyme was initiated with the growth of the organism and reached a peak after 18-20 h in the late logarithmic phase of growth, followed by a decline in the late stationary phase. This could be due to lysis of the cells, depletion of nutrients after vigorous growth or due to the accumulation of toxic metabolites21. Growth associated production of amylopullulanase was also reported in thermophilic species of Bacillus21 and Clostridium22. *Mean of three values, S.D within 10% Table 2—The amylopullulanase production in the optimized starch-yeast extract medium in flasks and fermenter Medium volume (mL) 50 100 200 400 10000 Volume of Fermentation Enzyme titre (U L -1)* flask time α-amylase Pullulanase (mL) (h) 250 20 2 850 830 500 20 2 856 840 1000 20 2 742 794 2000 20 2 665 713 22000 7 5 880 1900 *Mean of three values, S.D within 10% Fig. 4—Amylopullulanase production profile in the optimized amylopullulanase production medium in a laboratory fermenter Table 3—Summary of enzyme production in shake flasks and laboratory fermenter Enzyme titre (U L-1)* Levels of optimization Without optimization in shake flasks After optimization in shake flasks After optimization in Lab fermenter * Mean of three values, S.D with in 10% Fold increase α-amylase pullulanase α-amylase pullulanase 210 2 850 5 880 48 840 1900 1 14 28 1 17.5 39.5 342 INDIAN J BIOTECHNOL, JULY 2006 Temperature and pH are the two most important physical parameters that affect growth as well as secretion of extracellular enzymes. Temperature and pH optima for growth and enzyme production by G. thermoleovorans were 70°C and 7.0, respectively. Microorganisms are known to produce enzymes optimally at pH and temperature optimal for their growth4,19,21. Factors affecting proper mixing of nutrients and oxygen usually determine the optimal production of extracellular enzymes. Agitation rates in the range of 100 to 250 rpm are generally reported for the production of amylopullulanase from diverse bacteria19,22. The optimal agitation rate for G. thermoleovorans was within this range of agitation rates. The preference for this range of agitation may be due to proper balance of mixing of nutrients and their physical availability to the organism. At higher agitation rates, the uptake of nutrients from the outer environment may be hindered, as too little time is available for contact with substrates. This may lead to reduced uptake of substrates and other nutrients resulting in poor growth and production of enzymes23. The age and level of the inoculum are important parameters as they have a direct bearing on the growth pattern of the organisms. With increase in the inoculum level, there was a sharp fall in enzyme production after 2% (v/v). The production levels enhanced with increasing the age of the inoculum, and the optimal titres were attained with overnight grown culture in B. thermoamyloliquefaciens KP107124. In Bacillus sp. DSM 405, 1% inoculum of 2 h old culture supported a high enzyme production. Lower levels may be expected to take longer time to attain adequate cell numbers, while higher levels may lead to competition for nutrients19. Carbon sources provided for the growth and production of enzymes have a profound effect on the production behaviour of the organism. G. thermoleovorans grew very well on xylitol, sucrose, lactose and raffinose but the enzyme production was very low. The growth and enzyme titres were high in the presence of polysaccharides. Starch has been found to be the most preferred substrate for the production of amylopullulanases. Starch (1% w/v) has been very widely used3,20,25, although 2% starch was optimal for the production of amylopullulanase by B. subtilis4 as in G. thermoleovorans. Production of the enzyme was greater in soluble starch than in tapioca and corn starches, suggesting structural complexity of the raw starch grains. The choice of nitrogen source has also a significant influence on the secretion of amylopullulanases. Tryptone, an organic form of nitrogen, has been extensively used for the production of amylopullulanase by thermophiles, especially the hyperthermophiles23,25. Ammonium chloride and ammonium nitrate have also been used for the cultivation and enzyme production by Bacillus sp. 31833 and Bacillus sp. DSM 40519, respectively. Ammonium sulphate was used as a nitrogen source for production of the enzyme by B. circulans F-226, Bacillus sp. KSM-137827 and Bacillus sp. strain TS2320. The literature survey has suggested that the thermophilic bacilli appeared to have a preference for ammonium salts as source of nitrogen for the production of amylopullulanase. Our findings are consistent with this trend, and ammonium sulphate supported a high enzyme production in G. thermoleovorans. Magnesium ions play a critical role in diverse biological functions and their requirement may be expected for the growth and consequently enzyme production. At higher concentrations of Mg2+, the enzyme production was reduced, which may be due to blockage of protein release into the external medium as observed in the secretion of α-amylase from B. brevis No. 4728. Inorganic phosphate ions being constituents of cellular biomolecules such as cAMP, nucleic acids and coenzymes, play a regulatory role in the synthesis of primary and secondary metabolites in microorganisms29. There was a linear increase in the enzyme production with the increase in phosphate concentration but a sharp decline at higher concentrations. Most of the organisms producing amylopullulanase require yeast extract or other such complex compounds and trace elements for growth and enzyme production3,23,30,31. Mesophilic B. subtilis4 and Bacillus sp. KSM-137827 have also been shown to require micronutrients for enzyme production. There was no requirement of additional trace elements for enzyme production by T. thermosaccharolyticum25, Bacillus sp. DSM 40519 and Bacillus sp. strain TS2320. G. thermoleovorans appeared to have an obligate requirement for certain factor(s) available from yeast extract (vitamins) for growth, although additional trace elements were not necessary. The [ NOORVEZ et al: AMYLOPULLULANASE PRODUCTION BY G. THERMOLEOVORANS addition of copper and manganese to the production medium decreased the enzyme secretion, while cobalt enhanced it. There was, however, no increase in the biomass in presence of cobalt. Iron and calcium did not show any observable effect on the enzyme production. Presence of Triton X-100 in the production medium led to suppression of growth and enzyme secretion, while Tween-80 and SDS had no observable effect. Higher levels of detergents are known to disrupt the cell membrane of the bacterium leading to its lysis and consequently suppress growth32. Catabolite repression is one of the primary factors regulating the synthesis of exoenzymes33. Glucose and other easily matabolizable sugars did not repress the synthesis of enzyme in G. thermoleovorans. Amylopullulanases have been produced in the presence of glucose20, while some reports have shown repression of enzyme synthesis in the presence of glucose34. There is a great variation in the regulation of the exoenzyme synthesis as it may be inducible, partially or completely constitutive depending on the strain and the enzyme in question33. The majority of exoenzymes secreted by bacilli appeared to be at least partially inducible. Catabolic enzymes are normally induced by the enzyme substrate, but exoenzymes are an exception in that they are presumably excreted because the substrate is unable to enter the cell. The substrate, therefore, cannot be directly involved in the induction process. It is now generally accepted, that a low basal level of constitutive exoenzyme degrades its exogenous substrate and the resultant low molecular weight products enter the cell and induce further enzyme synthesis. These examples are relevant as the production of amylopullulanase by G. thermoleovorans demonstrated both the patterns. In addition to the induction of enzyme secretion by the presence of substrate, enzyme titres were further enhanced in the presence of maltose and maltodextrins. Maltotetraose has been shown to be an effective inducer of α-amylase synthesis in B. stearothermophilus35 and B. licheniformis36. Commercial malto-oligosaccharide mixture was used as an inducer for amylopullulanase production in Pyrococcus furiosus and Thermococcus litoralis23. The ratio of the medium volume to the volume of the flask determines the mixing properties of the nutrients as well as oxygen in conjunction with the agitation rate. With increasing medium volume at 343 fixed agitation rate, the mixing behaviour is expected to change, especially in the case of aerobic thermophiles where the amount of dissolved oxygen is already very low in comparison to ordinary temperatures. Shake flasks suffer from certain shortcomings, which affect production. Cotton plugs were found to limit oxygen transfer rates depending upon the quality of plugs. While swishing motion of flasks on a shaker does not allow proper oxygen transfer when medium volume is high. The production of metabolites in fermenters provides several advantages over shake flasks owing to better control over process parameters such as the control of pH and aeration besides better mixing of nutrients, heat and oxygen transfer37. When G. thermoleovorans was cultivated in the fermenter, there was neither improvement in enzyme production nor in growth as compared to shake flasks. The fermentation profile was similar in both, but the noticeable effect was reduction in production time from 18-20 h in flasks to 7-8 h in fermenter. This appeared to be due to improved process parameters such as mixing of nutrients as well as oxygen in the fermenter as compared to shake flasks37. The pH of the culture broth dropped from 7.0 to 4.7 accompanied by the growth of G. thermoleovorans as reported also in Fervidobacterium pennavorans Ven538 and 22 Clostridium sp. strain EM1 . The addition of 0.1% maltose as inducer and maintenance of pH at 7.0 led to a 2-fold increase in the enzyme titre. Since these are smaller molecules in comparison to starch, they could be easily taken up by the cells resulting in enhanced growth and secretion of enzyme. This enhanced level of excreted enzymes caused hydrolysis of starch35. The optimization of media components and cultural parameters has led to a marked enhancement in the production of amylopullulanase by G. thermoleovorans. In view of the potential applications of amylopullulanase in saccharification of starch into high maltose syrups in a single step and its potential application in baking as an antistale factor, further work on the production of amylopullulanase by G. thermoleovorans MTCC 4219 is needed to increase the enzyme production by induced mutagenesis. Acknowledgement The authors wish to thank Mr U Gangi Reddy and Mr M Dileep Kumar, and Mr S Krishnan of The INDIAN J BIOTECHNOL, JULY 2006 344 Energy and Resources Institute, New Delhi for their help in the end-product analysis by HPLC, and for 16S rRNA sequence analysis, respectively. We are grateful to the Department of Science & Technology, Government of India for the financial support through grant No.SP/SO/A89-98 during the course of this investigation. References 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Bauer M W, Driskill L E & Kelly R M, Glycosyl hydrolases from hyperthermophilic microorganisms, Curr Opin Biotechnol, 9 (1998) 141-145. Sonnleitner B, Biotechnology of thermophilic bacteria– Growth, products, and application, Adv Biochem Eng Biotechnol, 28 (1983) 69-138. Saha B C, Shen G-J, Srivastava K C, LeCureux L W & Zeikus J G, New thermostable α-amylase-like pullulanase from thermophilic Bacillus sp. 3183, Enzyme Microb Technol, 11(1989) 760-764. 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