Mattijs K. Julsing

Heme-iron oxygenases: powerful industrial biocatalysts?

Are cytochrome P450 enzymes powerful industrial biocatalysts? Next to market demands, well-defined enzyme functionalities and process parameters allow generalizations on the basis of process windows. These can provide useful guidelines for the design of improved biocatalysts. Oxygenase-catalyzed reactions are of special interest for selective C-H bond oxidation. The versatile class of cytochrome P450 mono-oxygenases attracts particular attention, and impressive advances have been achieved with respect to mechanistic insight, enzyme activity, stability, and specificity. Recent major achievements include significant increases in productivities, yields, and rates of catalytic turnover as well as modification of substrate specificity and efficient multistep reactions in whole-cell biocatalysts. For some biocatalysts, these parameters are already of an industrially useful magnitude.

Whole-cell biocatalysis for selective and productive C–O functional group introduction and modification

During the last decades, biocatalysis became of increasing importance for chemical and pharmaceutical industries. Regarding regio- and stereospecificity, enzymes have shown to be superior compared to traditional chemical synthesis approaches, especially in C-O functional group chemistry. Catalysts established on a process level are diverse and can be classified along a functional continuum starting with single-step biotransformations using isolated enzymes or microbial strains towards fermentative processes with recombinant microorganisms containing artificial synthetic pathways. The complex organization of respective enzymes combined with aspects such as cofactor dependency and low stability in isolated form often favors the use of whole cells over that of isolated enzymes. Based on an inventory of the large spectrum of biocatalytic C-O functional group chemistry, this review focuses on highlighting the potentials, limitations, and solutions offered by the application of self-regenerating microbial cells as biocatalysts. Different cellular functionalities are discussed in the light of their (possible) contribution to catalyst efficiency. The combined achievements in the areas of protein, genetic, metabolic, and reaction engineering enable the development of whole-cell biocatalysts as powerful tools in organic synthesis.

Outer Membrane Protein AlkL Boosts Biocatalytic Oxyfunctionalization of Hydrophobic Substrates in Escherichia coli

ABSTRACT The outer membrane of microbial cells forms an effective barrier for hydrophobic compounds, potentially causing an uptake limitation for hydrophobic substrates. Low bioconversion activities (1.9 U gcdw −1) have been observed for the ω-oxyfunctionalization of dodecanoic acid methyl ester by recombinant Escherichia coli containing the alkane monooxygenase AlkBGT of Pseudomonas putida GPo1. Using fatty acid methyl ester oxygenation as the model reaction, this study investigated strategies to improve bacterial uptake of hydrophobic substrates. Admixture of surfactants and cosolvents to improve substrate solubilization did not result in increased oxygenation rates. Addition of EDTA increased the initial dodecanoic acid methyl ester oxygenation activity 2.8-fold. The use of recombinant Pseudomonas fluorescens CHA0 instead of E. coli resulted in a similar activity increase. However, substrate mass transfer into cells was still found to be limiting. Remarkably, the coexpression of the alkL gene of P. putida GPo1 encoding an outer membrane protein with so-far-unknown function increased the dodecanoic acid methyl ester oxygenation activity of recombinant E. coli 28-fold. In a two-liquid-phase bioreactor setup, a 62-fold increase to a maximal activity of 87 U gcdw −1 was achieved, enabling the accumulation of high titers of terminally oxyfunctionalized products. Coexpression of alkL also increased oxygenation activities toward the natural AlkBGT substrates octane and nonane, showing for the first time clear evidence for a prominent role of AlkL in alkane degradation. This study demonstrates that AlkL is an efficient tool to boost productivities of whole-cell biotransformations involving hydrophobic aliphatic substrates and thus has potential for broad applicability.

Resting cells of recombinant E. coli show high epoxidation yields on energy source and high sensitivity to product inhibition

Metabolically active resting (i.e., nongrowing) bacterial cells have a high potential in cofactor‐dependent redox biotransformations. Where growing cells require carbon and energy for biomass production, resting cells can potentially exploit their metabolism more efficiently for redox biocatalysis allowing higher specific activities and product yields on energy source. Here, the potential of resting recombinant E. coli containing the styrene monooxygenase StyAB was investigated for enantioselective styrene epoxidation in a two‐liquid phase setup. Resting cells indeed showed twofold higher specific activities as compared to growing cells in a similar setup. However, product formation rates decreased steadily resulting in lower final product concentrations. The low intrinsic stability of the reductase component StyB was found to limit overall biocatalyst stability. Such limitation by enzyme stability was overcome by increasing intracellular StyB levels. Beyond that, product inhibition was identified as a limiting factor, whereas complete toxification of the bacterial cells, as it was observed with growing cells, and deactivation of the multicomponent enzyme system did not occur. The resting cell setup allowed high product yields on glucose of more than 5 mol mol  glucose−1 , which makes the use of resting cells a promising approach for ecologically as well as economically sustainable oxygenase‐based whole‐cell biocatalysis. Biotechnol. Bioeng. 2012; 109:1109–1119.

Whole-cell-based CYP153A6-catalyzed (S)-limonene hydroxylation efficiency depends on host background and profits from monoterpene uptake via AlkL

Living microbial cells are considered to be the catalyst of choice for selective terpene functionalization. However, such processes often suffer from side product formation and poor substrate mass transfer into cells. For the hydroxylation of (S)‐limonene to (S)‐perillyl alcohol by Pseudomonas putida KT2440 (pGEc47ΔB)(pCom8‐PFR1500), containing the cytochrome P450 monooxygenase CYP153A6, the side products perillyl aldehyde and perillic acid constituted up to 26% of the total amount of oxidized terpenes. In this study, it is shown that the reaction rate is substrate‐limited in the two‐liquid phase system used and that host intrinsic dehydrogenases and not CYP153A6 are responsible for the formation of the undesired side products. In contrast to P. putida KT2440, E. coli W3110 was found to catalyze perillyl aldehyde reduction to the alcohol and no oxidation to the acid. Furthermore, E. coli W3110 harboring CYP153A6 showed high limonene hydroxylation activities (7.1 U g  CDW−1 ). The outer membrane protein AlkL was found to enhance hydroxylation activities of E. coli twofold in aqueous single‐phase and fivefold in two‐liquid phase biotransformations. In the latter system, E. coli harboring CYP153A6 and AlkL produced up to 39.2 mmol (S)‐perillyl alcohol L  tot−1 within 26 h, whereas no perillic acid and minor amounts of perillyl aldehyde (8% of the total products) were formed. In conclusion, undesired perillyl alcohol oxidation was reduced by choosing E. colis enzymatic background as a reaction environment and co‐expression of the alkL gene in E. coli represents a promising strategy to enhance terpene bioconversion rates. Biotechnol. Bioeng. 2013; 110: 1282–1292.

Engineering the productivity of recombinant Escherichia coli for limonene formation from glycerol in minimal media

The efficiency and productivity of cellular biocatalysts play a key role in the industrial synthesis of fine and bulk chemicals. This study focuses on optimizing the synthesis of (S)‐limonene from glycerol and glucose as carbon sources using recombinant Escherichia coli. The cyclic monoterpene limonene is extensively used in the fragrance, food, and cosmetic industries. Recently, limonene also gained interest as alternative jet fuel of biological origin. Key parameters that limit the (S)‐limonene yield, related to genetics, physiology, and reaction engineering, were identified. The growth‐dependent production of (S)‐limonene was shown for the first time in minimal media. E. coli BL21 (DE3) was chosen as the preferred host strain, as it showed low acetate formation, fast growth, and high productivity. A two‐liquid phase fed‐batch fermentation with glucose as the sole carbon and energy source resulted in the formation of 700 mg Lorg–1 (S)‐limonene. Specific activities of 75 mU gcdw–1 were reached, but decreased relatively quickly. The use of glycerol as a carbon source resulted in a prolonged growth and production phase (specific activities of ≥50 mU gcdw–1) leading to a final (S)‐limonene concentration of 2,700 mg Lorg–1. Although geranyl diphosphate (GPP) synthase had a low solubility, its availability appeared not to limit (S)‐limonene formation in vivo under the conditions investigated. GPP rerouting towards endogenous farnesyl diphosphate (FPP) formation also did not limit (S)‐limonene production. The two‐liquid phase fed‐batch setup led to the highest monoterpene concentration obtained with a recombinant microbial biocatalyst to date.

Reaction and catalyst engineering to exploit kinetically controlled whole‐cell multistep biocatalysis for terminal FAME oxyfunctionalization

The oxyfunctionalization of unactivated CH bonds can selectively and efficiently be catalyzed by oxygenase‐containing whole‐cell biocatalysts. Recombinant Escherichia coli W3110 containing the alkane monooxygenase AlkBGT and the outer membrane protein AlkL from Pseudomonas putida GPo1 have been shown to efficiently catalyze the terminal oxyfunctionalization of renewable fatty acid methyl esters yielding bifunctional products of interest for polymer synthesis. In this study, AlkBGTL‐containing E. coli W3110 is shown to catalyze the multistep conversion of dodecanoic acid methyl ester (DAME) via terminal alcohol and aldehyde to the acid, exhibiting Michaelis–Menten‐type kinetics for each reaction step. In two‐liquid phase biotransformations, the product formation pattern was found to be controlled by DAME availability. Supplying DAME as bulk organic phase led to accumulation of the terminal alcohol as the predominant product. Limiting DAME availability via application of bis(2‐ethylhexyl)phthalate (BEHP) as organic carrier solvent enabled almost exclusive acid accumulation. Furthermore, utilization of BEHP enhanced catalyst stability by reducing toxic effects of substrate and products. A further shift towards the overoxidized products was achieved by co‐expression of the gene encoding the alcohol dehydrogenase AlkJ, which was shown to catalyze efficient and irreversible alcohol to aldehyde oxidation in vivo. With DAME as organic phase, the aldehyde accumulated as main product using resting cells containing AlkBGT, AlkL, as well as AlkJ. This study highlights the versatility of whole‐cell biocatalysis for synthesis of industrially relevant bifunctional building blocks and demonstrates how integrated reaction and catalyst engineering can be implemented to control product formation patterns in biocatalytic multistep reactions. Biotechnol. Bioeng. 2014;111: 1820–1830.

Efficient production of the Nylon 12 monomer ω-aminododecanoic acid methyl ester from renewable dodecanoic acid methyl ester with engineered Escherichia coli

The expansion of microbial substrate and product scopes will be an important brick promoting future bioeconomy. In this study, an orthogonal pathway running in parallel to native metabolism and converting renewable dodecanoic acid methyl ester (DAME) via terminal alcohol and aldehyde to 12-aminododecanoic acid methyl ester (ADAME), a building block for the high-performance polymer Nylon 12, was engineered in Escherichia coli and optimized regarding substrate uptake, substrate requirements, host strain choice, flux, and product yield. Efficient DAME uptake was achieved by means of the hydrophobic outer membrane porin AlkL increasing maximum oxygenation and transamination activities 8.3 and 7.6-fold, respectively. An optimized coupling to the pyruvate node via a heterologous alanine dehydrogenase enabled efficient intracellular L-alanine supply, a prerequisite for self-sufficient whole-cell transaminase catalysis. Finally, the introduction of a respiratory chain-linked alcohol dehydrogenase enabled an increase in pathway flux, the minimization of undesired overoxidation to the respective carboxylic acid, and thus the efficient formation of ADAME as main product. The completely synthetic orthogonal pathway presented in this study sets the stage for Nylon 12 production from renewables. Its effective operation achieved via fine tuning the connectivity to native cell functionalities emphasizes the potential of this concept to expand microbial substrate and product scopes.

Systematic optimization of a biocatalytic two-liquid phase oxyfunctionalization process guided by ecological and economic assessment

Next to economic success, ecological considerations have become increasingly important for companies synthesizing various compounds ranging from bulk chemicals to pharmaceuticals. In this context, the economic and ecological feasibility of asymmetric biocatalytic styrene epoxidation has previously been investigated and compared to chemical alternatives. Although the biotechnological two-liquid phase approach was found to be highly interesting in economic terms, the ecological performance is restrained by the applied organic carrier solvent bis(2-ethylhexyl)phthalate, which is toxic to humans and produced from non-renewable resources. As an alternative carrier solvent, the biodiesel constituent ethyl oleate was tested. Furthermore, the switch from glucose to glycerol as a carbon and energy source was investigated, the latter being a cheap abundant resource, as it is a waste product of the biodiesel and soap industries. Both strategies slightly reduced the productivity and final product titer. An ecological and economic assessment on process level, however, revealed a superior environmental performance (by 13%) with ethyl oleate as the extractive solvent, at the expense of slightly reduced economics (by 9%), whereas glycerol use reduced the performance with respect to both aspects. Based on available data, the application of resting cells was evaluated, providing the opportunity of more efficient carbon utilization via decoupling of growth and biotransformation. Their stability is, however, yet to be improved to achieve competitiveness. In general, this study underlines the potential of ecological and economic assessments for systematic process intensification. Even if advantages of proposed changes seem obvious, their true suitability can only be judged by detailed economic and ecological analyses at the process level.

Guiding efficient microbial synthesis of non-natural chemicals by physicochemical properties of reactants

The recent progress in sustainable chemistry and in synthetic biology increased the interest of chemical and pharmaceutical industries to implement microbial processes for chemical synthesis. However, most organisms used in biotechnological applications are not evolved by Nature for the production of hydrophobic, non-charged, volatile, or toxic compounds. In order to overcome this discrepancy, bioprocess design should consist of an integrated approach addressing pathway, cellular, reaction, and process engineering. Highlighting selected examples, we show that surprisingly often Nature provides conceptual solutions to enable chemical synthesis. Complemented by established methods from (bio)chemical and metabolic engineering, these concepts offer potential strategies yet to be explored and translated into innovative technical solutions enabling sustainable microbial production of non-natural chemicals.