3.1 Composition of Paper mulberry fruit juice (PMFJ) and preliminary evaluation of its fermentability
The ripe fruits of PM were highly juicy, constituting almost half of the fresh fruit weight (Table 2). This confers on it a succulent and delicate structure, and a consequent increased susceptibility to microbial degradation of its sugars (Choosung et al. 2019). As typical of sugar-based biomasses; prompt harvest, swift juice extraction and immediate storage of juice under appropriate conditions prior to fermentation, are very important steps to ensure sugar preservation (Klasson and Boone 2021). The total reducing sugar content of PM juice (glucose and fructose; 160.7 g/L) was basically the same with the total fermentable sugar (glucose, fructose and sucrose; 161.7 g/L) (Table 2), an indication that the juice contained trace or no amount of sucrose sugar. Similarly, the total soluble sugar composition in ripe fruits of Mulberry (Morus alba L.) which belonged to the same Moraceae family as Paper mulberry, had been reported to be made up of 80 % of reducing sugars (Lee and Hwang 2017). A sugar concentration of 150 – 200 g/L is considered desirable in industrial bioethanol production (Zabed et al. 2014). The rich fermentable sugar present in PMFJ is thus one of the indicators of its suitability as a high value feedstock for commercial bioethanol production. Furthermore, with almost all of the fermentable sugars being present in the forms of glucose and fructose monosaccharides, ethanol production might be initiated earlier due to rapid passage of directly fermentable sugar monomers into the yeast cells without prior hydrolysis in the yeast plasma membrane (D’Amore et al. 1989). It is interesting to note that the concentration of fermentable sugars in PMFJ compares favourably with that of some notable sugar-based bioenergy crops, except for sugar beets (table 3). However, remarkable variations exist in their sugar composition, whereby unlike PMFJ, sucrose is the dominant saccharide present in the juices of those sugar crops. The concentrations of minerals essential to yeast activities in PMFJ are shown in table 2. The proportions of each of these ions observed, are in agreement with an earlier study on the mineral composition of Paper mulberry fruits (Sun et al. 2012). The nutrient ions present in PMFJ are adequately sufficient to support a robust fermentation process, as all the essential metal ions, both macro and trace, were above the critical level required for yeast growth and metabolism (Walker 2014). This eliminates the need for external nutrient supplementation along with its associated costs, which is a big advantage in industrial bioethanol production.
Table 2 Paper mulberry fruit juice composition
Constituents
|
Concentration
|
Juice content (g/kg fruit)
|
442.86 ± 0.73
|
pH
|
5.12 ± 0.01
|
Total titratable acidity (g/L)
|
1.60 ± 0.00
|
sugar composition (g/L)
|
|
Total fermentable sugar
|
161.70 ± 1.04
|
Total reducing sugar
|
160.70 ± 0.21
|
mineral composition (mg/L)
|
|
K
|
2460.34 ± 5.2
|
Ca
|
303.65 ± 1.7
|
Mg
|
241.33 ± 3.3
|
Fe
|
25.40 ± 0.01
|
Zn
|
2.96 ± 0.00
|
Cu
|
0.82 ± 0.00
|
Mn
|
0.61 ± 0.00
|
Co
|
0.31 ± 0.00
|
Each parameter value is the mean of triplicate values ± standard deviation.
Table 3 Fermentable sugars in Paper mulberry fruit juice in comparison to juices of typical energy crops
Crop
|
Total fermentable sugar (g/L)
|
Principal fermentable sugar
|
References
|
Paper mulberry
|
161.7
|
Reducing sugars; 99 %
|
Current study
|
Sweet sorghum
|
94.5 – 170.0
|
Sucrose; 45 – 80 %
|
(Luo et al. 2014; Barcelos et al. 2016)
|
Sugar cane
|
151.0 – 187.0
|
Sucrose; 83 – 91 %
|
(Silva et al. 2017; Thammasittirong et al. 2017)
|
Sugar beet
|
240.6 – 679 8*
|
Sucrose; 92 – 99.5 %
|
(Grahovac et al. 2012; Gumienna et al. 2014)
|
*Expressed as g/kg of juice dry matter
To actually evaluate the potential of PMFJ as a viable feedstock for bioethanol production, preliminary batch fermentation study was carried out using 6 g/L yeast loading, for an incubation period of 96 hours, and at temperature and pH conditions of 35 ⁰C and 6, respectively. At the first 12 hours of fermentation, the sugar concentration in the fermentation broth had dropped drastically from 161.7 to 17.6 g/L, which corresponded to sugar consumption of 89.12 % by the yeast organisms (Fig. 1). Within the subsequent 12 hours, a relatively lower amount of sugar was taken up. Afterwards, no further uptake was observed due to depleting substrate concentration. With the high rate of sugar consumption, bioethanol was rapidly metabolized in the yeast cells, and moved from the intracellular membranes into the fermentation broth; leading to an ethanol concentration of 56.4 g/L, produced at a very high rate (productivity) of 4.7 g/L/hr within the first 12 hours (Fig. 1). This concentration was above the minimum level (40 g/L) required for a cost effective down-stream ethanol distillation process (Chen et al. 2016). At subsequent periods, concentration remained relatively constant, indicating that stationary phase of ethanol production was already achieved within half a day of the start of fermentation. The presence of metal ions (such as potassium, magnesium, zinc, calcium, manganese, iron, cobalt, and copper) in fermentation media play very crucial role in yeast cell metabolism as they primarily act as co-factors for a large number of enzymes involved in the production of bioethanol (Walker and Walker 2018). The inherent yeast-essential mineral nutrients in PMFJ were all above the threshold level required, which undoubtedly resulted to its excellent fermentability in terms of ethanol concentration, and productivity. Additionally, the quick rate of sugar uptake suggested the absence of components in the sugar substrate that could prove inhibitory to yeast cells, such as some toxic ions (Walker 2014). The rapid rate of sugar uptake by the yeast cells also seemingly confirmed our earlier speculation that with the directly fermentable glucose and fructose sugars being mainly present, movement of sugars into the yeast cells would be faster, as there would be no prior sucrose hydrolysis into its monomers in the yeast plasma membrane.
Bioethanol yield represents the amount of ethanol produced relative to the amount of sugar consumed. The higher the yield, the higher the portion of the total consumed sugar that was actually incorporated into the metabolic pathway of producing the desired product (bioethanol). Based on stoichiometric mass balance, the maximum theoretical yield of bioethanol from 1 g of consumed fermentable sugar monomer is 0.51 g. On a practical basis though, some sugars will expectedly be used up in some side reactions necessary for ethanol synthesis. Therefore, bioethanol yield corresponding to at least 90 % of the maximum theoretical yield (fermentation efficiency) is seen as being good in practice (Zabed et al. 2014). The obtained bioethanol yield of 0.39 g/g from fermentation of PMFJ was equivalent to 76.5 % of the maximum theoretical yield, which fell short of the minimal level. Nevertheless, from the overall performance of PMFJ during this preliminary trial, it can be concluded that this sugar substrate has great potentials for utilization in bioethanol production. In a subsequent evaluation, the fermentation performance of this novel biomass resource was further improved through optimization of process conditions.
3.2 Optimization of bioethanol production from Paper mulberry fruit juice
Response Surface Methodology (RSM) is one of the experimental models for obtaining optimum settings for a range of factors affecting a response variable(s) of interest. Three fermentation factors each at three coded levels were evaluated using Box-Behnken design of RSM to optimize ethanol concentration and productivity. Table 1 under Sect. 2.5 displays the fermentation conditions evaluated for the optimization. Unlike the preliminary study, minimal amounts of yeasts were this time employed (0.5–2 g/L), bearing in mind the nature of sugar substrate and its rapid uptake, as well as, economic considerations. The maximum temperature was extended to 40 ⁰C, with minimum of 20 ⁰C, while the pH values ranged from 4–6. Samples were withdrawn every eight hours for a whole duration of 80 hours. At the 16th hour, most of the treatment combinations had achieved stationary phases of sugar uptake and ethanol production. Therefore, data collected at this time-point were used for evaluation.
3.2.1 Bioethanol concentration and productivity responses to fermentation conditions of Paper Mulberry Fruit Juice
With the use of the quadratic polynomial function, the relationships of ethanol concentration and productivity with the three fermentation conditions of temperature, yeast concentration, and pH were described (Eqs. 1 and 2).
YEthanol concentration = 71.12 + 29.19X1 – 0.20X2 + 1.31X3 – 1.68 X1X2 – 0.59 X1X3 – 1.21 X2X3 – 28.43X12 – 0.63X22 + 1.18X32 ………................................................. (1)
YEthanol productivity = 4.44 + 1.19X1 + 0.02X2 + 0.11X3 – 0.18X1X2 – 0.08 X1X3 – 0.08 X2X3 – 1.14X12 − 0.04X22 + 0.08X32 ……............................................................... (2)
The analysis of variance (ANOVA) for the quadratic models of ethanol concentration, and productivity were highly significant, as p < 0.0001, and p = 0.0001, respectively (Table 4). This indicated that the models for the regression terms were adequate, and that a higher order model would not be needed. As seen in the R-square values of the models, more than 99 % of variations in the both responses could be explained by the factors of fermentation conditions, reflecting the model reliability. The models for the two responses passed the lack of fit test, as p values were higher than 0.05, showing that the experimental data fitted well to the model design, and could suitably be used for prediction purpose. The less than 5 % coefficient of variation (CV) was a proof of the reproducibility and reliability of experimental data.
Table 4 ANOVA for the quadratic models of ethanol concentration (g/L), and productivity (g/L/hr.)
Sources of variance
|
Ethanol conc.
|
|
Ethanol prod.
|
|
|
Sum of sq.
|
F value
|
P value
|
Sum of sq.
|
F-value
|
P value
|
Model
|
9885.36
|
226.42
|
<0.0001
|
16.47
|
69.87
|
0.0001
|
Temperature - X1
|
6818.78
|
1405.66
|
<0.0001
|
11.28
|
430.61
|
<0.0001
|
Yeast conc. - X2
|
0.30
|
0.06
|
0.8122
|
0.00
|
0.17
|
0.6953
|
pH - X3
|
13.73
|
2.83
|
0.1533
|
0.09
|
3.45
|
0.1225
|
X1X2
|
11.39
|
2.33
|
0.1876
|
0.13
|
4.81
|
0.0798
|
X1X3
|
1.39
|
0.28
|
0.6151
|
0.03
|
1.04
|
0.3548
|
X3X4
|
5.86
|
1.21
|
0.3219
|
0.02
|
0.86
|
0.3966
|
X12
|
2985.41
|
615.43
|
<0.0001
|
4.81
|
183.70
|
<0.0001
|
X22
|
1.47
|
0.30
|
0.6062
|
0.01
|
0.27
|
0.6225
|
X32
|
5.14
|
1.06
|
0.3505
|
0.02
|
0.92
|
0.3813
|
Lack of fit
|
20.87
|
4.12
|
0.2016
|
0.12
|
5.37
|
0.1610
|
R2
|
0.9976
|
|
|
0.9921
|
|
|
CV
|
3.92
|
|
|
3.85
|
|
|
Based on the p values of the three fermentation conditions considered, only temperature had a highly significant main linear effects on the two dependent variables (Table 4). There were positive responses of ethanol concentration and productivity to increases in temperature, with linear coefficients of 29.19, and 1.19, respectively, (Eqs. 1 and 2). None of the interaction effects of the fermentation factors on the both responses were significant, which made generation of the 3D surface plot of the experimental factors unnecessary. This non-significant interaction effects also signalled that the remarkable impact exhibited by temperature basically remained the same, irrespective of the prevailing yeast concentration and pH within the range considered. Bioethanol concentration and productivity exhibited no significant quadratic responses to yeast concentration and pH, but had a highly significant curve relationship with fermentation temperature. However, unlike the temperature main effect, quadratic impact of temperature caused a significant reduction in the responses, as indicated by the negative values of the coefficients in the polynomial functions. Therefore, the optimal region for each dependent variable in response to temperature, was a maximum rather than minimum (i.e., the curvature is convex). This meant that while bioethanol concentration and productivity initially responded positively to increases in temperature, a further unit increase in temperature above the optimal level, would result to significant reductions in these responses at magnitudes of -28.43, and − 1.14, respectively, (Eqs. 1 and 2).
The observed and predicted values of ethanol concentration and productivity as a function of fermentation conditions were shown in Table 5. The observed values varied from 9.61–76.51 g/L, and 1.72–4.78 g/L/hr, respectively. Based on the amount of substrate consumed, this corresponded to yields of 0.18–0.51 g/g (35–98 % of the maximum theoretical yields/ fermentation efficiencies). The predicted values of the responses by the model matched closely with the actual experimental data obtained, as revealed by the very small residual values. Yeast concentration and pH within the ranges evaluated were not critical process conditions influencing ethanol titre and rate of formation, though generally there were slight negative responses at lower values of these predictor factors. At same conditions of yeast loading and pH, an increase in temperature above 20 ⁰C resulted to significant improvements in ethanol concentration. There were increases from 16.21–72.31 g/L (runs #4 vs #10), 14.12–72.70 g/L (runs #11 vs #14), 9.61–72.47 g/L (runs #2 vs #8), and 15.00–71.14 g/L (runs #7 vs #13). The same trend was also observed in the rate of ethanol production, from 2.36–4.52 g/L/hr (runs #4 vs #10), 2.08–4.54 g/L/hr (runs #11 vs #14), 1.72–4.53 g/L/hr (runs #2 vs #8), and finally from 2.34–4.44 g/L/hr (runs #7 vs #13). These tremendous increases matched well with the rate of sugar consumption. At just 16 hours of fermentation, stationary phase of sugar uptake had been achieved by most runs at which fermentation temperature was above 20 ⁰C. On the other hand, sugar metabolism was really slow at 20 ⁰C, resulting to a much later attainment of stationary phase at 32–40 hours (table S1).
Table 5 The actual and predicted values for ethanol concentration (g/L) and productivity (g/L/hr.)
Runs
|
Codes
|
|
|
Ethanol concentration
|
|
Ethanol productivity
|
|
|
X1
|
X2
|
X3
|
Observed
|
Predicted
|
Residual
|
Observed
|
Predicted
|
Residual
|
|
|
|
|
|
|
|
|
|
|
1
|
30
|
2
|
4
|
69.25
|
71.38
|
-2.13
|
4.33
|
4.47
|
-0.14
|
2
|
20
|
0.5
|
5
|
9.61
|
11.38
|
-1.77
|
1.72
|
1.87
|
-0.15
|
3
|
30
|
0.5
|
6
|
76.51
|
74.39
|
2.12
|
4.78
|
4.64
|
-0.14
|
4
|
20
|
1.25
|
6
|
16.21
|
16.57
|
-0.36
|
2.36
|
2.38
|
0.00
|
5
|
30
|
1.25
|
5
|
69.82
|
71.12
|
-1.30
|
4.36
|
4.44
|
-0.08
|
6
|
30
|
1.25
|
5
|
71.12
|
71.12
|
0.00
|
4.44
|
4.44
|
-0.00
|
7
|
20
|
2
|
5
|
15.00
|
14.35
|
0.65
|
2.34
|
2.27
|
0.07
|
8
|
40
|
0.5
|
5
|
72.47
|
73.13
|
-0.65
|
4.53
|
4.60
|
0.09
|
9
|
30
|
1.25
|
5
|
72.42
|
71.12
|
1.30
|
4.53
|
4.44
|
-0.07
|
10
|
40
|
1.25
|
6
|
72.31
|
73.78
|
-1.47
|
4.52
|
4.59
|
0.08
|
11
|
20
|
1.25
|
4
|
14.12
|
12.77
|
1.47
|
2.08
|
2.01
|
0.15
|
12
|
30
|
0.5
|
4
|
69.64
|
69.35
|
0.29
|
4.35
|
4.28
|
-0.00
|
13
|
40
|
2
|
5
|
71.14
|
69.38
|
1.76
|
4.44
|
4.29
|
-0.08
|
14
|
40
|
1.25
|
4
|
72.70
|
72.34
|
0.36
|
4.54
|
4.55
|
-0.01
|
15
|
30
|
2
|
6
|
71.28
|
71.58
|
-0.29
|
4.46
|
4.54
|
-0.08
|
Temperature has been implicated as the top factor having strong impact on fermentation performance by yeast cells (Lin et al. 2012; Zabed et al. 2014; Bhadana and Chauhan 2016; Mohd Azhar et al. 2017). For one, it affects fluidity of yeast membranes, subsequently impacting on the passage of solutes into and out of cells (Zabed et al. 2014). Over a 168-hour incubation, Lin et al. (2012) observed that increasing the temperature from 10 to 20, and then 30 ⁰C shortened the exponential growth period of yeast cells to 120 and 48 hours, respectively. He concluded that the quicker onset of stationary phase was initiated as a result of increased cell division and metabolic activities. Similarly in our study, at each evaluated temperature, a comparison of the residual sugar in fermentation broth with the corresponding bioethanol concentration and rate of production, revealed a strong inverse relationship (fig. S1). The poor fermentation performance at the low temperature of 20 ⁰C was therefore a consequence of reduced uptake of fermentable sugar molecules for conversion into bioethanol, owing to a decreased yeast metabolic rate. With increase in temperature beyond 20 ⁰C and up to a point, sugar uptake was improved tremendously (varying from 89.5–95.2 % consumption). Bioethanol was rapidly metabolized in the yeast cells, and moved from within the cells into the fermentation broth leading to a high ethanol concentration, and attainment of stationary phase at just the 16th hour of incubation. However, much higher increase in temperature up to 40 ⁰C presented a stress factor to yeast cells, which led to significant reductions in ethanol production. There was also a corresponding increase in the amount of residual sugar, indicating inhibited substrate uptake (table S1). The metabolic and physical mechanisms behind this inhibition have been reported to include inactivation of regulatory enzymes, denaturation of yeast ribosomes, and change in fluidity of yeast membranes which hindered inter and intracellular solute movement, resulting to accumulation of toxins in yeast cells and reduced uptake of the much needed carbon substrate (Walker 1998). It is worth stating that even at extreme temperature condition of 40 ⁰C, the concentrations of bioethanol from PMFJ (71.14–72.70 g/L) was still above the minimum requirement (40 g/L) for industrial fermentation, and the maximum productivity realized (4.52–4.54 g/L/hr) exceeded many reported values in literature from the fermentation of other sugar substrates (Table 7). This could be related to the abundant availability of minerals in the juice especially Mg2+ ions, as this mineral has been reported to exert a membrane protective effects on yeast cells, enabling an enhanced ethanol production even under temperature stress (Eardley and Timson 2020; Walker and Basso 2020).
Table 7 Bioethanol production from PMFJ compared to some notable sugar-based substrates using S. cerevisiae
Feedstocks
|
Initial total sugar conc. (g/L)
|
Dominant sugar
|
Temp. (⁰C)
|
Yeast conc. (g/L)
|
pH
|
Nutrient addition
|
Time (hrs.)
|
Ethanol conc. (g/L)
|
Fermentation efficiency (%)
|
Ethanol productivity (g/L/hr)
|
References
|
Paper mulberry fruit juice
|
162
|
Reducing sugars; 99 %
|
35
|
0.55
|
5
|
Nil
|
16
|
73.7
|
94
|
4.6
|
Current work
|
Sweet sorghum juice
|
95
162
|
Sucrose; 45 %
Sucrose; 78 %
|
35
37
|
1
12
|
5
4.5
|
Nil
Nil
|
72
11
|
49.5
72
|
101
87
|
2.4
6.5
|
(Luo et al. 2014)
(Barcelos et al. 2016)
|
Sugar cane juice
|
230
153 – 187
|
Sucrose
Sucrose; 87 – 93 %
|
30
37
|
20
5 x 105 cells/ml
|
5
5
|
Nil
Nil
|
24
36
|
79.2
9.1 – 10.7
|
-
87 – 90
|
3.3
0.25 – 0.30
|
(Giri et al. 2013)
(Thammasittirong et al. 2017)
|
Sugar beets thin juice concentrate
Sugar beets thick juice
Sugar beets raw juice
|
200
210
136
|
Sucrose
Sucrose; 99%
Sucrose
|
30
30
28
|
1
3
10
|
5
5
5
|
Yes
Nil
Nil
|
72
46
20
|
91.2
86.3
66.3
|
86
94
94
|
1.3
1.9
4.2
|
(Kawa-Rygielska et al. 2013)
(Grahovac et al. 2012)
(Dodić et al. 2012)
|
Banana fruit waste
|
485
|
-
|
35
|
50
|
6
|
Yes
|
168
|
24.1
|
-
|
-
|
(Matharasi et al. 2018)
|
Grape fruit waste
|
-
|
-
|
30
|
10
|
5.6
|
Nil
|
36
|
58.2
|
-
|
1.6
|
(Dular 2019)
|
Jamaica cherry fruit juice
|
-
|
-
|
34
|
80
|
6
|
Yes
|
630
|
74.0
|
-
|
-
|
(Thangadurai et al. 2014)
|
Varying literature reports exist with respect to the influence of yeast concentration on bioethanol production. According to the findings of Matharasi et al. (2018) on batch fermentation of Banana fruit waste, increasing the yeast loadings from 1–5 %, progressively improved bioethanol concentration significantly. Conversely, in a review of several studies on yeast bioethanol production, Mohd Azhar et al. (2017) reported that while higher inoculum sizes had no effect on the final ethanol concentration, it markedly influenced the rate of ethanol formation (productivity), through reduction of incubation period, due to more rapid sugar uptake by the large yeast cells population. In an optimization modelling of bioethanol production from Sweet sorghum juice, Luo et al. (2014) noted no significant effect on both the final ethanol concentration and ethanol productivity, under the evaluated yeast loadings of 0.5–2 g/L. Similarly in the present research, increase in the yeast cell concentrations within the range used (0.5–2 g/L), had no significant effect on ethanol concentration, and productivity. Even if higher levels of yeast loadings were to be used in our study, the possibility of observing a significant effect is not justified. This is in consideration of the fact that during the preliminary investigations to evaluate fermentability of PMFJ, the ethanol productivity and concentration realized using 6 g/L of yeast cells (Fig. 1), were respectively at par with and even lower than that obtained under the minimal yeast levels used in the optimization study, at similar temperature and pH conditions (Table 5). Therefore, the excellent performance of PMFJ even at very low yeast inputs could be due to substrate-related factors, which include its rich essential mineral nutrients’ status, the fermentable sugars being mostly composed of glucose and fructose monosaccharides which facilitated quicker conversion to bioethanol, as well as the absence of any yeast-inhibitory factor in the must that could impair cells activities.
The H+ concentration (pH) of the fermentation broth affects nutrients permeability into the yeast cells, which in extension influences yeast metabolism, ethanol production, and by-product formation (Lin et al. 2012; Zabed et al. 2014) In our study, while there were negative responses of ethanol concentration, and productivity to low pH value of 4, the impact of pH was not significant.
3.2.2 Numerical optimization and validation of model prediction
Optimization was achieved based on the criteria of maximizing bioethanol concentration, and productivity, while keeping the temperature, yeast concentration and pH in range settings. The optimized fermentation conditions predicted by the model were temperature of 35 ⁰C, yeast concentration of 0.55g/L, and pH of 5.0, which would result to ethanol concentration, and productivity of 79.14g/L, and 4.78 g/L/hr, respectively. These optimal fermentation conditions suggested by the model were verified by performing the corresponding experiment to establish its validity. The actual responses of ethanol concentration, and productivity subsequently obtained were all within the 95 % confidence interval (Table 6), confirming the model prediction.
Table 6 Confirmation of the optimized fermentation conditions predicted by the model
Responses
|
Predicted value
|
95 % CI*a
|
Observed value
|
Concentration (g/L)
|
79.14
|
72.47 – 85.83
|
73.69*b
|
Productivity (g/L/hr)
|
4.78
|
4.29 – 5.27
|
4.61
|
*a Confidence interval
*bBased on the amount of sugar consumed, this represented a yield of 0.48g/g (94 % of the maximum theoretical yield)
With the use of S. cerevisiae in batch fermentation, different optimal process conditions have been reported for several sugar-based feedstocks (table 7). While the ideal temperature and pH established for the fermentation of PMFJ were well within the ranges generally reported in literatures, the yeast concentration optima differed greatly. Interestingly, even at relatively very low yeast concentration and non-supplementation of external nutrients, bioethanol production from PMFJ compared favourably with some notable sugar-based energy crops, and even exceeded most other sugar-based feedstocks, which boosts its economic suitability by way of reductions of process time and cost. This novel biomass can actually be utilized as a great resource for bioethanol production, having met and surpassed the industrial conditions for acceptability including, sugar concentration (150 – 200 g/L), ethanol titre (> 40 g/L), ethanol productivity (> 1 g/L/hr), and fermentation efficiency (> 90 %).