a microbial polyhydroxyalkanoates (pha) based bio- and materials industry

13
A microbial polyhydroxyalkanoates (PHA) based bio- and materials industry Guo-Qiang Chen* ab Received 5th January 2009 First published as an Advance Article on the web 8th May 2009 DOI: 10.1039/b812677c Biopolyesters polyhydroxyalkanoates (PHA) produced by many bacteria have been investigated by microbiologists, molecular biologists, biochemists, chemical engineers, chemists, polymer experts and medical researchers. PHA applications as bioplastics, fine chemicals, implant biomaterials, medicines and biofuels have been developed and are covered in this critical review. Companies have been established or involved in PHA related R&D as well as large scale production. Recently, bacterial PHA synthesis has been found to be useful for improving robustness of industrial microorganisms and regulating bacterial metabolism, leading to yield improvement on some fermentation products. In addition, amphiphilic proteins related to PHA synthesis including PhaP, PhaZ or PhaC have been found to be useful for achieving protein purification and even specific drug targeting. It has become clear that PHA and its related technologies are forming an industrial value chain ranging from fermentation, materials, energy to medical fields (142 references). 1. Introduction Polyhydroxyalkanoates (PHA), as a family of diverse biopolyesters, 1 have gone through many years of efforts towards commercialization, with limited successes. Beginning in the 1980s, many companies have tried to produce various PHA on pilot or industrial scales (Table 1) based on the expectation that petroleum prices would increase due to its exhaustion and people might be willing to use environmentally friendly non-petrochemical based plastics, termed biodegradable plastics, green plastics, bioplastics or ecoplastics. 2 Scientific breakthroughs led to the successful large scale production of poly-(R)-3-hydroxybutyrate (PHB) by Chemie Linz AG Austria, copolymer PHBV of (R)-3-hydroxybutyrate (3HB) and (R)-3-hydroxyvalerate (3HV) by ICI UK and TianAn China, and copolymer PHBHHx of (R)-3-hydroxybutyrate (3HB) and (R)-3-hydroxy- hexanoate (3HHx) by the joint efforts of Tsinghua University, KAIST and P&G (Table 1). Many applications have also been developed based on the availability of the above PHA (Table 4). New molecular biology technology contributes more and more to these industrial breakthroughs. Beginning in 2009, Metabolix (USA) and Tianjin Green Bioscience (China) will produce 50 000 and 10 000 tons/year of PHA, respectively (Table 1). By then, global polymer companies should have sufficient PHA materials to research with. A new wave of PHA development with a focus on new applications is expected soon. However, the petroleum price did not increase significantly, resulting in the closure of many PHA related projects in some companies (Table 1). Right after 2001, the petroleum price began a sharp increase. In mid-2008, $140 per barrel was reached. This has promoted the development of plastics that may be independent of petroleum. Two polyesters, namely polylactic acid (PLA) and PHA, come into play, each has its advantages and disadvantages (Table 2). Typically, PLA is cheaper and PHA more expensive yet application properties can be varied, depending on the co-monomer structures and content in the copolyesters. Since PLA has been available in large quantity, its application research is ahead of PHA’s. The recent energy crisis has prompted a renewed interest in producing PHA with a competitive edge compared with other bulk plastics including the already mass produced PLA, which possesses similar biodegradability and sustainability (Table 2). Although the cost of petroleum has been drawn down by the Professor Guo-Qiang CHEN obtained his BSc from South China University of Technology in 1985 and PhD from Graz University of Technology in Austria in 1989. He has been focusing his research on micro- bial polyhydroxyalkanoates (PHA) since 1986. With 20+ years of basic research and R&D experience on PHA production and applications, he is currently heading the Laboratory of Microbiology at Tsinghua University and the Multidisciplinary Research Center at Shantou University, and has contributed to the founding of several PHA based biotech companies in China. Guo-Qiang Chen a Dept Biological Sciences and Biotechnology, Tsinghua University, Beijing 100084, China. E-mail: [email protected]; Fax: 0086-10-62794217; Tel: 0086-10-62783844 b Multidisciplinary Research Center, Shantou University, Shantou 515063, China. E-mail: [email protected]; Fax: 0086-754-82901175; Tel: 0086-754-82901186 2434 | Chem. Soc. Rev., 2009, 38, 2434–2446 This journal is c The Royal Society of Chemistry 2009 CRITICAL REVIEW www.rsc.org/csr | Chemical Society Reviews Published on 08 May 2009. Downloaded by FAC DE QUIMICA on 23/09/2013 23:13:51. View Article Online / Journal Homepage / Table of Contents for this issue

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  • A microbial polyhydroxyalkanoates (PHA) based bio- andmaterials industry

    Guo-Qiang Chen*ab

    Received 5th January 2009

    First published as an Advance Article on the web 8th May 2009

    DOI: 10.1039/b812677c

    Biopolyesters polyhydroxyalkanoates (PHA) produced by many bacteria have been investigated

    by microbiologists, molecular biologists, biochemists, chemical engineers, chemists, polymer

    experts and medical researchers. PHA applications as bioplastics, ne chemicals, implant

    biomaterials, medicines and biofuels have been developed and are covered in this critical review.

    Companies have been established or involved in PHA related R&D as well as large scale

    production. Recently, bacterial PHA synthesis has been found to be useful for improving

    robustness of industrial microorganisms and regulating bacterial metabolism, leading to yield

    improvement on some fermentation products. In addition, amphiphilic proteins related to PHA

    synthesis including PhaP, PhaZ or PhaC have been found to be useful for achieving protein

    purication and even specic drug targeting. It has become clear that PHA and its related

    technologies are forming an industrial value chain ranging from fermentation, materials, energy

    to medical elds (142 references).

    1. Introduction

    Polyhydroxyalkanoates (PHA), as a family of diverse

    biopolyesters,1 have gone through many years of eorts

    towards commercialization, with limited successes.

    Beginning in the 1980s, many companies have tried to

    produce various PHA on pilot or industrial scales (Table 1)

    based on the expectation that petroleum prices would increase

    due to its exhaustion and people might be willing to use

    environmentally friendly non-petrochemical based plastics,

    termed biodegradable plastics, green plastics, bioplastics or

    ecoplastics.2 Scientic breakthroughs led to the successful

    large scale production of poly-(R)-3-hydroxybutyrate

    (PHB) by Chemie Linz AG Austria, copolymer PHBV of

    (R)-3-hydroxybutyrate (3HB) and (R)-3-hydroxyvalerate

    (3HV) by ICI UK and TianAn China, and copolymer

    PHBHHx of (R)-3-hydroxybutyrate (3HB) and (R)-3-hydroxy-

    hexanoate (3HHx) by the joint eorts of Tsinghua University,

    KAIST and P&G (Table 1). Many applications have also been

    developed based on the availability of the above PHA

    (Table 4). New molecular biology technology contributes

    more and more to these industrial breakthroughs. Beginning

    in 2009, Metabolix (USA) and Tianjin Green Bioscience

    (China) will produce 50 000 and 10 000 tons/year of PHA,

    respectively (Table 1). By then, global polymer companies

    should have sucient PHA materials to research with. A

    new wave of PHA development with a focus on new applications

    is expected soon.

    However, the petroleum price did not increase signicantly,

    resulting in the closure of many PHA related projects in some

    companies (Table 1). Right after 2001, the petroleum price

    began a sharp increase. In mid-2008, $140 per barrel was

    reached. This has promoted the development of plastics that

    may be independent of petroleum. Two polyesters, namely

    polylactic acid (PLA) and PHA, come into play, each has its

    advantages and disadvantages (Table 2). Typically, PLA is

    cheaper and PHA more expensive yet application properties

    can be varied, depending on the co-monomer structures and

    content in the copolyesters. Since PLA has been available in

    large quantity, its application research is ahead of PHAs.

    The recent energy crisis has prompted a renewed interest in

    producing PHA with a competitive edge compared with other

    bulk plastics including the already mass produced PLA, which

    possesses similar biodegradability and sustainability (Table 2).

    Although the cost of petroleum has been drawn down by the

    Professor Guo-Qiang CHEN

    obtained his BSc from South

    China University of Technology

    in 1985 and PhD from Graz

    University of Technology in

    Austria in 1989. He has been

    focusing his research on micro-

    bial polyhydroxyalkanoates

    (PHA) since 1986. With 20+

    years of basic research and

    R&D experience on PHA

    production and applications,

    he is currently heading the

    Laboratory of Microbiology at

    Tsinghua University and the

    Multidisciplinary Research Center at Shantou University, and

    has contributed to the founding of several PHA based biotech

    companies in China.

    Guo-Qiang Chen

    aDept Biological Sciences and Biotechnology, Tsinghua University,Beijing 100084, China. E-mail: [email protected];Fax: 0086-10-62794217; Tel: 0086-10-62783844

    bMultidisciplinary Research Center, Shantou University,Shantou 515063, China. E-mail: [email protected];Fax: 0086-754-82901175; Tel: 0086-754-82901186

    2434 | Chem. Soc. Rev., 2009, 38, 24342446 This journal is c The Royal Society of Chemistry 2009

    CRITICAL REVIEW www.rsc.org/csr | Chemical Society Reviews

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  • nancial tsunami in late 2008, PHA as a bioplastic has been

    considered as useful for reducing CO2 emissions. To achieve

    the mass production and application of PHA, eorts should be

    made on eectively lowering the PHA production cost.3

    In addition, more PHA applications should be developed,

    including the high value added ones.

    Over the past years, PHA as polymeric materials have been

    developed into applications in plastics, medical implants,

    drug delivery carriers, printing and photographic materials,

    nutritional supplements, drugs and ne chemicals.49

    Recently, PHA has been found useful as a new type of

    biofuel.10 In addition, PHA related proteins and genes have

    been used to regulate metabolisms and to enhance the

    robustness of industrial microorganisms,11,12 even for specic

    drug targeting13 and protein purications.1416 Its applications

    are rapidly expanding.

    This paper reviews what has been achieved and what should

    be done to make PHA competitive as bulk plastics, chemicals,

    biofuels or other relative applications. An outlook for PHA

    development is also provided (Table 5).

    2. Fermentation industry: PHA production

    Since PHA are produced by large scale microbial fermentation, it

    contributes to the fermentation industry, much like the

    antibiotic industry started in the early 1920s. So far, PHB,

    PHBV, P3HB4HB, PHBHHx and mcl PHA are produced in

    large scale (Table 3).

    PHA production involves strain development, shake ask

    optimization, lab and pilot fermentor studies and then industrial

    scale up (Fig. 1). Eective microbial production of PHA

    depends on several factors, including the nal cell density,

    bacterial growth rate, percentage of PHA in cell dry weight,

    time taken to reach high nal cell density, substrate to product

    transformation eciency, price of substrates and a convenient

    and cheap method to extract and purify the PHA (Fig. 1).

    Table 1 Worldwide PHA producing and researching companies

    Company Types of PHA Production scale (t/a) Period Applications

    ICI, UK PHBV 300 1980s to 1990s PackagingChemie Linz, Austria PHB 20100 1980s Packaging & drug deliverybtF, Austria PHB 20100 1990s Packaging & drug deliveryBiomers, Germany PHB Unknown 1990s to present Packaging & drug deliveryBASF, Germany PHB, PHBV Pilot scale 1980s to 2005 Blending with EcoexMetabolix, USA Several PHA Unknown 1980s to present PackagingTepha, USA Several PHA PHA medical implants 1990s to present Medical bio-implantsADM, USA (with Metabolix) Several PHA 50 000 2005 to present Raw materialsP&G, USA Several PHA Contract manufacture 1980s to 2005 PackagingMonsanto, USA PHB, PHBV Plant PHA production 1990s Raw materialsMeredian, USA Several PHA 10 000 2007 to present Raw materialsKaneka, Japan (with P&G) Several PHA Unknown 1990s to present PackagingMitsubishi, Japan PHB 10 1990s PackagingBiocycles, Brazil PHB 100 1990s to present Raw materialsBio-On, Italy PHA (unclear) 10 000 2008 to present Raw materialsZhejiang Tian An, China PHBV 2000 1990s to present Raw materialsJiangmen Biotech Ctr, China PHBHHx Unknown 1990s Raw materialsYikeman, Shandong, China PHA (unclear) 3000 2008 to present Raw materialsTianjin Northern Food, China PHB Pilot scale 1990s Raw materialsShantou Lianyi Biotech, China Several PHA Pilot scale 1990s to 2005 Packaging and medicalJiang Su Nan Tian, China PHB Pilot scale 1990s to present Raw materialsShenzhen OBioer, China Several PHA Unknown 2004 to present UnclearTianjin Green Bio-Science (+DSM) P3HB4HB 10 000 2004 to present Raw materials & packagingShandong Lukang, China Several PHA Pilot scale 2005 to present Raw materials & medical

    Table 2 Comparison between polylactic acid (PLA) and polyhydroxyalkanoates (PHA)

    PLA vs. PHA PLA PHA

    Monomer structures Only D- and L-lactic acids (LA) At least 150 monomersProduction methods Bio-production of LA and chemical synthesis of PLA Totally biosynthesized as intracellular polyestersProduction cost Comparable with conventional plastics like PET At least twice that of PLAMaterial properties Poor, could be adjusted by regulating D- and L-LA

    ratiosFrom brittle, exible to elastic, fully controllable

    Technology maturity LA production well established, yet LA polymerizationto PLA is complicated. Only one company,NatureWork, produces PLA on a large scale

    At least 10 companies worldwide produced or areproducing PHA up to 2000 t per year scale viamicrobial fermentation

    Investment Large xed capital investment: NatureWork hasinvested 1 billion US$ over the past several years to runa 140 000 ton PLA plant

    Small investment: existing aerobic microbial fer-mentation plants with process modications canbe used for PHA production

    Intellectual properties Cover almost all areas of production and applications Still a lot of spaces for exploitationApplication areas Packaging, medical implants, printing, coating et al., yet

    limited by Tg of 6575 1C for cheaper P(L-LA)Almost all areas of conventional plastic industry,limited only by current higher cost

    This journal is c The Royal Society of Chemistry 2009 Chem. Soc. Rev., 2009, 38, 24342446 | 2435

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  • Various factors must be considered in dierent stages of

    development. Both wild type and recombinant bacteria were

    used for large scale production of various PHA (Table 3).

    For large scale application, PHA production costs should be

    as low as possible. Therefore, energy saving micro-aerobic

    processes, and, increasingly, the use of waste water or activated

    sludges for PHA production should be paid attention to. This

    requires the development of industrial strains or even mixed

    cultures that are capable of growing in low intensity aeration and

    producing high content PHA within a reasonable period of time.

    Microbial production of PHA by wild type strains

    Ralstonia eutropha (formerly called Alcaligenes eutrophus,

    Wautersia eutropha, or Cupriavidus necator) has been the most

    commonly used wild type strain for the industrial production

    of poly-(R)-3-hydroxybutyrate (PHB),17 poly((R)-3-hydroxy-

    butyrate-co-4-hydroxybutyrate) (P3HB4HB)18 and poly((R)-

    3-hydroxybutyrate-co-(R)-3-hydroxyvalerate) (PHBV)19 (Table 3).

    The strain was able to grow to a density of over 100 g l1 after72 h (ICI, UK). The highest cell density of over 200 g l1

    containing over 80% PHB was observed in a one cubic metre

    fermentor after 60 h of fermentation (Tianjin Northern Food

    Co. Ltd). When glucose was fed together with propionate,

    160 g l1 cell dry weight containing over 75% PHBV wasproduced over 48 h of growth in a ve cubic metre fermentor

    (Zhejiang Tian An Co. Ltd, China) (Table 3). R. eutropha and

    recombinant E. coli could grow to over 100 g l1 containingover 75% P3HB4HB after 100 h of fermentation in a one cubic

    metre fermentor vessel (Tianjin Green Bioscience Co. Ltd).

    All these results indicated that R. eutropha and recombinant

    Table 3 Wild type and industrial bacterial strains commonly used for pilot and large scale production of PHAa

    StrainDNAmanipulation

    PHA type andscale (t/a) C-Source

    Final CDW(g l1)

    Final PHA(% CDW) Company (Table 1)

    Ralstonia eutropha No PHB (10) Glucose 4200 480% Tianjin North. Food, ChinaAlcaligenes latus No PHB (10300) Glucose or

    sucrose460 475% Chemie Linz, btF, Austria

    Biomers, GermanyEscherichia coli phbCAB + vgb PHB (10) Glucose 4150 480% Jiang Su Nan Tian, ChinaRalstonia eutropha No PHBV

    (3002000)Glucose +propionate

    4160 475% ICI, UKZhejiang Tian An, China

    Ralstonia eutropha No P3HB4HB(410 000)

    Glucose +1,4-BD

    4100 475% Metabolix, USAEscherichia coli phbCAB Tianjin Green Biosci. ChinaRalstonia eutropha phaCAc PHBHHx (1) Fatty acids 4100 480% P&G, Kaneka, JapanAeromonas hydrophila No PHBHHx (1) Lauric acid o50 o50% P&G, Jiangmen Biotech Ctr,

    ChinaAeromonas hydrophila phbAB + vgb PHBHHx (0.1) Lauric acid B50 450% Shandong Lukang,Pseudomonas putida No mcl PHA (0.1) Fatty acids B45 460% ETH, SwitzerlandP. oleovoransBacillus spp. No PHB (5) Sucrose 490 450% Biocycles, Brazila CDW: cell dry weight; vgb: gene encoding Vitreoscilla hemoglobin; phbCAB: PHB synthesis genes encoding b-ketothiolase, acetoacetyl-CoAreductase and PHB synthase; A. caviae: Aeromonas caviae; 1,4-BD: 1,4-butanediol; phaCAc: PHA synthase gene phaC from Aeromonas caviae;

    phbAB encodes b-ketothiolase and acetoacetyl-CoA reductase.

    Fig. 1 Strain and process development for industrial production of PHA.

    2436 | Chem. Soc. Rev., 2009, 38, 24342446 This journal is c The Royal Society of Chemistry 2009

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  • E. coli were and will be important industrial strains for the

    production of at least the three PHAmentioned above due to its

    simplicity of growth requirements. Recently, the whole

    genome of R. eutropha was sequenced,20 allowing more genetic

    manipulations on the PHA production related pathways.

    Alcaligenes latus, similar to R. eutropha in terms of PHA

    production, was used for PHB and PHBV production

    by Chemie Linz AG, Austria and later Biotechnologische

    Forschungsgesellschaft (btF, Austria), then Biomers

    (Germany).17,21 A. latus in a lab scale 1 L fermentor was

    reported to reach a cell density of 142 g l1 containing 50%PHB after just 18 h of growth.22

    Aeromonas hydrophila was employed for large scale

    production of random copolymer poly((R)-3-hydroxybutyrate-

    co-(R)-3-hydroxyhexanoate) (PHBHHx) in a 20 000 L fermentor.

    A nal cell concentration, PHBHHx concentration and PHA

    content of 50 g l1, 25 g l1, and 50 wt%, respectively, wereobtained in 46 h.23 Wild type A. hydrophila is not an eective

    PHBHHx producer.

    Pseudomonas oleovorans grown on n-alkanes was reported

    to produce 63 wt% PHA containing medium-chain-length

    (mcl) monomers in its cell dry weight with a volumetric

    PHA productivity of 1.06 g l1 h1.24 The wide choice ofsubstrates and the low substrate specicity of PHA synthase

    PhaC enable P. oleovorans and P. putida to synthesize over

    100 PHA with various monomer structures.25,26

    Microbial production of PHA by recombinant strains

    Recombinant E. coli has been commonly employed for PHA

    production due to its convenience for genetic manipulation,

    fast growth, high nal cell density and ability to utilize

    inexpensive carbon sources. Metabolix and Jiang Su Nan Tian

    Co. Ltd. employed recombinant E. coli for their PHA

    production (Table 3). A recombinant E. coli harboring the

    PHA synthetic genes phbCAB from R. eutropha and bacterial

    hemoglobin gene vgb produced a cell dry weight of 206 g l1

    containing 73% PHB with a productivity of 3.4 g l1 h1.2729

    A starch hydrolysis capable recombinant E. coli VG1

    harboring phbCAB, vgb and lytic genes of phage lambda

    grown on starch produced 167 g l1 PHB with a productivityof 3.05 g l1 h1, a simple temperature-inducing treatment ledto 95% PHB purity recovered.29

    Recombinant E. coli can also be used to produce other PHA

    including poly-4-hydroxybutyrate (P4HB) homopolymer,30

    copolymer P3HB4HB,31 and PHBVHHx terpolymer of

    (R)-3-hydroxybutyrate (HB), (R)-3-hydroxyvalerate (HV)

    and (R)-3-hydroxyhexanoate (HHx).32,33

    Recombinant E. coli containing the phaC1 gene from

    P. aeruginosa was able to produce medium-chain-length

    PHA from fatty acids when the beta-oxidation gene fadB

    was deleted.33

    R. eutropha PHB-4 unable to accumulate PHA is the PhaC

    mutant of wild type strain R. eutropha. Recombinant

    R. eutropha PHB-4 containing PHA synthase gene phaC

    from Aeromonas caviae produced PHBHHx from fatty acids

    including palm olein, crude palm oil and palm acid oil,34,35

    approximately 87 wt% PHBHHx containing 5 mol% HHx

    was obtained.36

    Recombinant Aeromonas hydrophila 4AK4 harboring

    phbAB or phaPCJ was able to accumulate terpolyesters of

    PHBVHHx or P3HB4HB3HHx of HB, 4-hydroxybutyrate

    (4HB) and HHx.37,38 A. hydrophila 4AK4, harboring a

    truncated tesA gene encoding cytosolic thioesterase I of E. coli

    which catalyzes the conversion of acyl-ACP into free fatty

    acids, was able to synthesize PHBHHx containing 1014 mol%

    HHx using gluconate and glucose rather than fatty acids.39 To

    enhance PHBHHx production by A. hydrophila, vgb gene

    encoding Vitreoscilla haemoglobin or fadD gene encoding

    E. coli acyl-CoA synthase was co-expressed with PHA

    synthesis related genes including phbAB from R. eutropha

    and phaPCJ from A. hydrophila, leading to at least 20%

    increases in PHBHHx and HHx content.40

    P. putida KT2442 is a well-known mcl PHA producer

    with its whole genomic DNA fully sequenced.41 Using

    suicide plasmid pK18mobsacB, beta-oxidation genes fadA

    and fadB knock-out mutants of P. putida KT2442

    produced 84% intracellular mcl PHA consisting of 41 mol%

    3-hydroxydodecanoate (HDD), signicantly higher than its

    wild type strain KT2442, which produces around 50% mcl

    PHA containing only 8.5 mol% HDD. A higher HDD

    fraction surprisingly increased crystallization degree and

    tensile strength of the mcl PHA.42 When tetradecanoate was

    fed, P. putida KTOY06 produced about 80% mcl PHA

    containing over 30% 3-hydroxytetradecanoate (HTD).43

    Anaerobic PHA production

    Recombinant E. coli anaerobically accumulated PHB to more

    than 50% of its cell dry weight during cultivation in either

    growth or nongrowth medium.44 The maximum theoretical

    carbon yield for anaerobic PHB synthesis in E. coli is 0.8,

    much higher than the aerobic one of 0.48. Anaerobic PHA

    production is perhaps one of the most important ways to

    reduce PHA production cost. However, the slow growth of

    bacteria under anaerobic conditions must be considered.

    Vijayasankaran et al.45 constructed a tandem gene expression

    cassette containing three R. eutropha PHB synthesis genes

    under the control of the Pichia pastoris glyceraldehyde-3-

    phosphate promoter and the green uorescent protein (GFP)

    under the control of the P. pastoriss alcohol oxidase promoter.

    Oxygen stress led to increased PHB production. PHB exceeding

    30% of CDW of recombinant P. pastoris appeared to be the

    consequence of the decreased biomass growth rate under

    severe oxygen limitation.45 Therefore, micro-aerobic process

    appears to be more attractive as it combines the advantages of

    low energy cost and fast growth.46

    PHA production from waste materials

    Waste materials or waste water can be used to produce

    PHA, which provides a cost reduction. Khardenavis et al.47

    evaluated waste activated sludge generated from a combined

    dairy and food processing industry waste water treatment

    plant for PHB production. Deproteinized jowar grain-based

    distillery spentwash yielded 42.3 wt% PHB, followed by 40

    wt% PHB from ltered rice grain-based distillery spentwash.

    Addition of diammonium hydrogen phosphate (DAHP)

    resulted in an increase in PHB production to 67% when raw

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  • rice grain-based spentwash was used. The same waste water

    after removal of suspended solids by ltration and with DAHP

    supplementation resulted in lower PHB production (57.9%).

    However, supplementing other wastes with DAHP led to a

    substantial decrease in PHB content in comparison to what

    was observed in the absence of DAHP.47 Such study indicates

    the feasibility of using waste water for PHA production.

    Mixed culture production of PHA from waste water was

    nancially attractive in comparison to pure culture PHA

    production.48 Both PHA production processes had similar

    environmental impacts that were signicantly lower than high

    density polyethylene (HDPE) production. A large potential

    for optimisation exists for the PHA process as nancial and

    environmental costs were primarily due to energy use for

    downstream processing.49 Therefore, mixed culture bio-

    technology could become an attractive addition or alternative

    to traditional pure culture based biotechnology for the

    production of PHA, other chemicals and/or bioenergy,47

    especially, mixed culture could become stable and continuous.

    3. Energy industry: biofuels based on PHA

    PHA including poly-(R)-3-hydroxybutyrate (PHB) and medium-

    chain-length PHA (mcl PHA) were respectively converted to

    (R)-3-hydroxybutyrate methyl ester (3HBME) and medium

    chain length hydroxyalkanoate methyl ester (3HAME) by acid

    catalyzed hydrolysis.10 It was found that 3HBME and 3HAME

    had combustion heat values of 20 kJ g1 and 30 kJ g1,respectively. Ethanol has a combustion heat of 27 kJ g1 whileaddition of 10% 3HBME or 3HAME enhanced the combustion

    heat of ethanol to 30 kJ g1 and 35 kJ g1, respectively. Theaddition of 3HBME or 3HAME into n-propanol and n-butanol

    led to slight reductions in their combustion heats. Combustion

    heats of blended fuels 3HBMEdiesel or 3HBMEgasoline and

    of 3HAMEdiesel or 3HAMEgasoline were lower than that of

    pure diesel or gasoline but were reasonable as fuels. It was

    roughly estimated that the production costs of PHA based

    biofuels from waste resources including waste water and

    activated sludges should be around US$1200 per ton.10

    Since biofuels including ethanol and biodiesel have always

    had controversy regarding food vs. fuel and fuel vs.

    arable land, PHA based biofuel production from waste water

    or from activated sludge enjoys the advantages of waste water

    treatment accompanied by energy generation. This result

    opens a new area for PHA application in the energy sector.

    4. Material industry: PHA as polymeric materials

    Owing to its special polymer features, PHA with diverse

    structures and properties have been researched as bioplastics,

    bers, biomedical implants and drug delivery carriers et al.49

    (Table 4). Similar to the rapid development of polylactic acid

    (PLA) promoted by NatureWork as a bulk bioplastic, the

    large scale supply of PHA will speed up its development as

    new plastics with sustainable properties.

    PHA as biodegradable plastics and ber materials

    PHA were initially used to make everyday articles such

    as shampoo bottles and packaging materials by Wella AG

    Germany.50 PHA were also developed as packaging lms

    mainly for use as shopping bags, containers and paper

    coatings, disposable items such as razors, utensils, diapers,

    feminine hygiene products, cosmetic containers and cups, as

    well as medical surgical garments, upholstery, carpets, packaging,

    compostable bags and lids or tubs for thermoformed

    articles by P&G, Biomers, Metabolix and several other

    companies.2,51,52

    PHB bers with high tensile strength were prepared by

    stretching the bers after isothermal crystallization near

    the glass transition temperature.53 Increasing the time for

    isothermal crystallization of PHB bers resulted in a decrease

    in the maximum draw ratio. Yet the tensile strength of PHA

    bers increased remarkably when the isothermal crystallization

    time was prolonged to more than 24 h. The tensile strength of

    low-molecular-weight drawn bers was higher than that of

    high-molecular-weight bers.53 PHB bers stretched after

    isothermal crystallization had the oriented alpha-form crystal

    with a 2(1) helix conformation and the beta-form with a planar

    zigzag conformation.53

    Vogel et al.54 attempted to use reactive extrusion

    with peroxide as a comfortable pathway for improving the

    crystallization of PHB in a melt spinning process. They

    succeeded in improving the crystallization in the spinline and

    Table 4 Applications of PHA in various elds

    Applications Examples

    Packagingindustry

    All packaging materials that are used for a shortperiod of time, including food utensils, lms,daily consumables, electronic appliances et al.

    Printing &photographicindustry

    PHA are polyesters that can be easily stained111

    Other bulkchemicals

    Heat sensitive adhesives, latex, smart gels. PHAnonwoven matrices can be used to remove facialoils

    Blockcopolymerization

    PHA can be changed into PHA diols for blockcopolymerization with other polymers

    Plastic processing PHA can be used as processing aids for plasticprocessing

    Textile industry Like nylons, PHA can be processed into bersFine chemicalindustry

    PHA monomers are all chiral R-forms, and canbe used as chiral starting materials for thesynthesis of antibiotics and other ne chemicals8

    Medical implantbiomaterials

    PHA have biodegradability and biocompatibility,and can be developed into medical implantmaterials.9 PHA can also be turned into drugcontrolled release matrices

    Medical PHA monomers, especially R3HB, havetherapeutic eects on Alzheimers andParkinsons diseases, osteoporosis and evenmemory improvement et al.8991

    Healthy foodadditives

    PHA oligomers can be used as food supplementsfor obtaining ketone bodies58

    Industrialmicrobiology

    The PHA synthesis operon can be used as ametabolic regulator or resistance enhancer toimprove the performances of industrial microbialstrains95101

    Biofuels or fueladditives

    PHA can be hydrolyzed to form hydroxy-alkanoate methyl esters that are combustible10

    Proteinpurication

    PHA granule binding proteins phasin or PhaP areused to purify recombinant proteins14,102109

    Specic drugdelivery

    Coexpression of PhaP and specic ligands canhelp achieve specic targeting to diseasedtissues13

    2438 | Chem. Soc. Rev., 2009, 38, 24342446 This journal is c The Royal Society of Chemistry 2009

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  • the inhibition of the secondary crystallization in the bers.54

    These processes overcame the brittleness of PHA and created

    very strong bers with promising applications.

    PHA as medical implant materials

    PHA including PHB, PHBV, P3HB4HB, P4HB, P3HO

    (poly-(R)-3-hydroxyoctanoate) and PHBHHx are frequently

    investigated for use as sutures, repair devices, repair patches,

    slings, cardiovascular patches, orthopedic pins, adhesion

    barriers, stents, guided tissue repair/regeneration devices,

    articular cartilage repair devices, nerve guides, tendon repair

    devices, bone marrow scaolds, articial oesophagus and

    wound dressings.9 Boston based company Tepha specializes

    in manufacturing pericardial patches, artery augments,

    cardiological stents, vascular grafts, heart valves, implants

    and tablets, sutures, dressings, dusting powders and prodrugs;

    it markets P4HB for medical application under the name of

    PHA4400.55 Recently, PHBHHx was successfully used as an

    osteosynthetic material for stimulating bone growth owing to

    its piezoelectric properties,56 and for eectively repairing

    damaged nerves.57 Oligomers of PHA were found to have

    nutritional and therapeutic uses.58

    Shishatskaya et al. found that the monolament sutures

    made of PHB and PHBV did not cause any in vivo acute

    vascular reaction at the site of implantation or any adverse

    event for more than one year.59 Similar phenomena have been

    discovered with PHBHHx.60 One of the most important issues

    for PHBHHx as an implant biomaterial is the non-toxicity and

    lack of immuno-stimulation properties of its degradation

    products including monomers and oligomers,6163 they

    even stimulate the Ca2+-channel activation and promote

    regeneration of damaged tissues.

    With successful approval of P4HB as an implant bio-

    material, more PHA based biomaterials are expected to go

    into clinical trials soon. With the diversity of PHA materials,

    one can expect the PHA to become a family of bioimplant

    materials with rich applications.

    PHA as drug delivery carrier

    Homo- and co-polymers of lactate and glycolate are widely

    used in commercially available sustained release products for

    drug delivery. However, lactate and glycolate co-polymers are

    degraded by bulk hydrolysis. Hence drug release can not be

    fully controlled.64 In the early 1990s, PHA became candidates

    for use as drug carriers due to their biodegradability,

    biocompatibility and their degradation by surface erosion.65

    PHA used as a drug carrier was reviewed in 1989 by Koosha

    et al.66 The potential of matrices produced by direct compression

    of PHBV for oral administration has been proven with the

    benets of simplied processing over alternative sustained

    release technologies.67 Increasing the polymer molecular mass

    caused an increased rate of sulfamethizole release from

    irregularly shaped PHB microparticles.68 When comparing the

    in vitro and in vivo release of the anti-cancer agent lomustine

    from PHB and PLA microspheres as potential carriers for drug

    targeting, it was found that the drug was released from the PHB

    microspheres faster.69 Incorporation of ethyl- or butyl esters of

    fatty acids into the PHB microspheres increased the rate of the

    drug release.70

    So far only PHB and PHBV have been studied for drug

    controlled release, it is expected that other PHA family

    members with diverse properties will bring more control

    release properties for the drug release eld. This is still an

    area that remains to be exploited.

    5. Fine chemical industry: PHA chiral monomers

    More than 120 dierent structures of carboxylic acids

    hydroxylated at the 3-, 4-, 5-, or 6-position, all in the

    (R)-conguration if they possess a chiral center at the position

    of the hydroxyl group, have been reported in PHA with an

    increasing number of new monomers being discovered.71,72 In

    addition, if the cells are under carbon limitation, the accumu-

    lated PHA can be degraded to the monomers and can be

    reutilized by the bacteria as a carbon and energy source which

    can also serve to produce PHA monomers.73 Due to the chiral

    purity, modiable OH and COOH groups and some other

    special characteristics, PHA monomers have attracted much

    attention in industry and academic areas. Technology for

    production of PHA monomers by chemical synthesis,

    biotransformation, chemical degradation and enzymatic

    degradation has been developed.8

    Production of PHA monomers by microorganisms

    Various enantiomerically pure (R)-3-hydroxyalkanoic acids

    (RHA) can be conveniently prepared by depolymerizing the

    biosynthesized PHA. A method for producing (R)-3-hydroxy-

    butyric acid (R3HB) and (R)-3-hydroxyvaleric acid (R3HV)

    from PHB and PHBV by chemical degradation has been

    reported.74 de Roo et al. produced the chiral (R)-3-hydroxy-

    alkanoic acid and (R)-3-hydroxyalkanoic acid methyl esters

    via hydrolytic degradation of polyhydroxyalkanoates synthe-

    sized by Pseudomonads.75 They rst hydrolyzed the recovered

    PHA by acid methanolysis and then distilled the 3-hydroxy-

    alkanoic acid methyl ester mixture into several fractions.

    Subsequently, the (R)-3-hydroxyalkanoic acid methyl esters

    were saponied to yield the corresponding 3-hydroxyalkanoic

    acid with nal yields of the RHA up to 92.8% (w/w).

    Lee and co-workers demonstrated that R3HB could be

    eciently produced via in vivo depolymerization by providing

    the appropriate environmental conditions.76 In their study

    with the strain Alcaligenes latus, they found that lowering

    the pH to 34 induced the highest activity of intracellular PHB

    depolymerase and blocked the reutilization of R3HB by the

    cells.76 Ren et al. suspended the PHA containing Pseudomonas

    putida cells in phosphate buer at dierent pH. When the pH

    was 11, the degradation and monomer release were at their

    best.77 Under the conditions, 3-hydroxyoctanoic acid (R3HO)

    and 3-hydroxyhexanoic acid (R3HHx) were degraded with an

    eciency of over 90% (w/w) in 9 h and the yields of the

    corresponding monomers were also over 90%. Under the same

    conditions, unsaturated monomers 3-hydroxy-6-heptenoic

    acid, 3-hydroxy-8-nonenoic acid and 3-hydroxy-10-undecenoic

    acid were also produced though in a lower yield compared

    with the saturated monomer.77

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  • Wild type E. coli DH5a was engineered to produce extra-cellular R3HB by simultaneous expression of PHB precursor

    genes of b-ketothiolase (phbA), acetoacetyl-CoA reductase(phbB), phosphor-transbutyrylase (ptb) and butyrate kinase

    (buk). A batch process run in a 5 L fermentor produced

    approximately 5 g l1 3HB after 24 h. A fed-batchprocess increased R3HB production to 12 g l1 after 48 h offermentation.78

    Medium-chain-length (R)-3-hydroxyhexanoic acid (R3HHx)

    and (R)-3-hydroxyoctanoic acid (R3HO) were produced by

    over-expressing PHA depolymerase gene phaZ, together

    with putative long chain fatty acid transport gene fadL of

    Pseudomonas putida KT2442 and acyl-CoA synthetase (fadD)

    of E. coli MG1655 in P. putida KT2442. In a 48 h fed-batch

    fermentation process conducted in a 6 L fermentor with 3 L

    sodium octanoate mineral medium, 5.8 g l1 extracellularR3HHx and R3HO were obtained in the fermentation broth.79

    Now that chiral PHA monomers can be produced using

    dierent ways, the cost of the chiral hydroxyalkanoic acids is

    no longer an issue hindering their applications. With proper

    scale up, the chiral PHA monomers can become bulk

    chemicals for various applications.

    Applications of PHA monomers

    The PHA-origin RHA monomers contain a chiral center and

    two easily modied functional groups (OH and COOH).

    Therefore, one of the important applications for RHA is to

    be valuable synthons and to act as starting materials for

    the synthesis of ne chemicals such as antibiotics, vitamins,

    aromatics and pheromones.80

    The dierent RHA will have dierent physiological impacts.

    Therefore, the diversied types of RHA will sometimes

    have dierent functions. It was reported that some RHA

    exhibit specic important biological activities such as

    antimicrobial or antiviral potential while other RHA do not.

    For example, (R)-3-hydroxy-n-phenylalkanoic acid was used

    to eectively attack Listeria monocytogenes, which is a

    ubiquitous microorganism, able to multiply at refrigeration

    temperatures and is resistant to both high temperature and

    low pH.81,82

    The most common PHA monomer, namely R3HB has been

    used as the starting material for producing carbapenem anti-

    biotics and macrolides.83 A novel class of polymers named

    dendrimers was also synthesized using R3HB. Besides the

    application as building blocks of chiral compounds, RHA

    monomers can also be used to synthesize novel chiral poly-

    esters. Two new 3-hydroxyalkanoates: 3-hydroxy-3-cyclo-

    propylpropionate and 3-hydroxy-4-chlorobutyrate and their

    CoA thioester derivatives have been successfully synthesized.84

    Some peptides modied by the RHA exhibit novel features

    and better application abilities.85,86 Novel b- and g-peptideswere produced by replacing amino acids by 3-hydroxybutyrate

    residues in peptides and by replacing the chain bound oxygens

    in 3HB or 4HB with NH. These novel peptides showed

    better resistance to peptidases and environmental microbial

    degradation and longevity in mammalian serum. Some

    of these peptides even possessed useful antibacterial, anti-

    proliferative and haemolytic properties.85,86

    Ketone bodies, including R3HB, can correct defects in

    mitochondrial energy generation in the heart. R3HB was

    administered into rats in hemorrhagic hypotension and the

    plasma concentration of substrates related to glucose metabolism

    was evaluated.87 The results suggest that administered R3HB

    may suppress glycolysis during hemorrhagic shock.

    One of the biggest advantages for R3HB is that it has good

    tolerance in humans and a short half-life in vivo. Therefore,

    R3HB was directly used as an oral drug. Recently, R3HB has

    been employed to treat traumatic injuries that benet from

    elevated levels of ketone bodies such as hemorrhagic shock,

    extensive burns, myocardial damage, and cerebral hypoxia,

    anoxia, and ischemia.8890 Furthermore, R3HB has been

    found to be able to reduce the death rate of the human

    neuronal cell model culture for Alzheimers and Parkinsons

    diseases and to ameliorate the appearance of corneal epithelial

    erosion through suppression of apoptosis; R3HB methyl

    ester was also found to dramatically improve the memory

    of mice.8991

    R3HB was found to have a stimulatory eect on cell cycle

    progression of murine broblast L929 cells, human umbilical

    vein endothelial cells, and rabbit articular cartilages that are

    mediated by a signaling pathway dependent upon increases in

    [Ca2+].92

    R3HB was clearly demonstrated to have a positive eect on

    the growth of osteoblasts in vitro and on anti-osteoporosis

    in vivo.93 It was found that R3HB increased serum alkaline

    phosphatase activity and calcium deposition, decreased

    serum osteocalcin, prevented bone mineral density reduction

    resulting from ovariectomization, leading to enhanced femur

    maximal load and bone deformation resistance, as well as

    improved trabecular bone volume.93

    So far, most of the applications of PHA monomers are

    based on R3HB due to its availability in sucient quantities.

    With the availability of other chiral monomers, new PHA

    monomer based polymers and new medical applications of

    chiral R3HA will emerge rapidly. Again, this is an area waiting

    for exploitation.

    6. The application of the PHA synthesismechanism for improving industrial microorganisms

    There have been many reports on the physiological functions

    of PHA, mostly centered on increasing the survival ability

    under adverse conditions such as starvation, desiccation, UV

    radiation, high osmotic pressure and the presence of organic

    solvents et al.94 It was also reported that the ability to

    accumulate PHB makes the bacteria more responsive to

    sudden increases in substrate concentrations, which explains

    their ecological advantage.94,95

    Feast and famine cycles are common in activated sludge

    waste water treatment systems, and they select for bacteria

    that accumulate storage compounds, such as PHB.94 Recently,

    Zhao et al. compared the survival abilities of a PHBHHx

    producing strain Aeromonas hydrophila 4AK4 and its

    corresponding PhaC-disrupted mutant termed A. hydrophila

    CQ4. It was found that PHBHHx synthesis in the wild type

    strain A. hydrophila 4AK4 provided the strain with improved

    resistance against environmental stress factors including heat

    2440 | Chem. Soc. Rev., 2009, 38, 24342446 This journal is c The Royal Society of Chemistry 2009

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  • and cold treatments, hydrogen peroxide, UV irradiation,

    ethanol and high osmotic pressure.96 The real-time PCR study

    revealed that the synthesis of PHBHHx enhanced the expression

    levels of sigma factor ss encoded by groS.95,96 Therefore, itmay be possible to improve the robustness of some industrial

    microorganisms for the benet of fermentation processes. In

    addition, PHA synthesis that consumes a lot of acetyl-CoA

    and NADH may be used to help regulate certain microbial

    metabolisms for enhanced product formation.

    For example, Streptococcus zooepidemicus is an important

    strain for the industrial production of hyaluronic acid for

    cosmetic applications. In the hyaluronic acid fermentation

    process, S. zooepidemicus produces a large amount of lactic

    acid, which consumes a great deal of carbon source and is

    harmful to the microbial cells. When PHB synthesis genes

    phbCAB of R. eutrophawere transformed into S. zooepidemicus,

    the recombinant produced only 40 g l1 lactic acid and 7.5 g l1

    hyaluronic acid, whereas the wild type produced 65 g l1

    lactic acid and 5.5 g l1 hyaluronic acid.97 The enhancedproduction of hyaluronic acid via introducing the phbCAB

    genes was explained by the regulatory eects of PHB synthesis

    pathway on the cellular oxidation/reduction potential. This

    study successfully demonstrated that the PHA synthesis

    related to energy and carbon metabolism could be employed

    as a pathway to regulate other cellular metabolism and possibly

    to regulate the production of other metabolic products.97

    Another example, Corynebacterium glutamicum, a

    gram-positive soil bacterium, has been used extensively for

    the industrial production of L-glutamate and other amino

    acids. C. glutamicum harboring phbCAB from R. eutropha

    accumulated 3B13% PHB when grown on glucose.L-Glutamate production increased to 39B68% in twoC. glutamicum strains harboring PHB synthesis genes

    compared with their wild type parent strains in shake ask

    experiments. In fermentor studies, the recombinant produced

    approximately 23% more L-glutamate compared with that of

    the wild type, and yielded less intermediate metabolites or

    by-products including a-ketoglutarate, L-glutamine andlactate. These results suggested that the expression of phbCAB

    genes in C. glutamicum helped regulate glutamate production

    metabolism. This demonstrated that the expression of PHB

    synthesis genes has a positive eect on L-glutamate production

    in C. glutamicum.98

    In addition, methanol production from carbon dioxide

    was successfully achieved using resting cells of Methylosinus

    trichosporium IMV 3011 as biocatalysts. It was found that the

    catabolism of stored PHB can provide intracellular reducing

    equivalents to improve the intrinsic methanol production

    capacity. It appeared that the total methanol production

    capacity was increased with increasing PHB content in cells.

    Resting cells containing 38.6% PHB exhibited the highest total

    methanol production capacity. The eects of the methanol

    production process on the survival and recovery of

    M. trichosporium IMV 3011 showed that the methanol

    production from carbon dioxide reduction was not detrimental

    to the viability of methanotrophs.99

    As molecular evidence for PHA synthesis related to

    enhanced stress resistance, Han et al. analyzed and compared

    the proteomes of a metabolically engineered E. coli under

    PHB-production and non-PHB-production conditions.100 The

    proteome expression patterns of the recombinant strain were

    resolved on 2D gels. It was found that three heat shock

    proteins, GroEL, GroES, and DanK were signicantly

    up-regulated in the PHB-accumulating cells. The expression

    of the yD gene encoding a 14.3 kDa protein, which is known

    to be produced at low pH, was greatly induced with the

    accumulation of PHB. This may be a good indication for

    enhancing the E. coli stress resistance by introducing the PHA

    biosynthesis pathways. Generally, results in this research

    indicated that accumulation of PHB in E. coli acted as a stress

    on the cells, which reduced the cells ability to synthesize

    proteins and induced the expression of various protective

    proteins,100 these proteins help improve the robustness of the

    strains.

    When PHB biosynthesis operon phbCAB was fused with the

    promoter of pyruvate decarboxylase of Zymomonas mobilis,

    and then the pBBR1MCS-1 plasmid containing the fused

    genes was introduced into Z. mobilis, the expression of PHB

    in Z. mobilis was achieved. The shake-ask fermentation

    results showed that the recombinant strains accumulated

    10% more ethanol than the wild type strain after culturing

    the strains for 48 h.101

    It has become clear that the PHA synthesis mechanism that

    improves the anti-stress ability of non-PHA producers, can

    be borrowed to improve the yield of non-PHA producing

    industrial strains that are constantly under environmental

    stresses including changing temperature, pH, substrate types

    and concentrations et al.

    7. Application of PHA granule surface proteins

    Several kinds of proteins are found to locate on the surface of

    in vivo PHA granules.102,103 Among these proteins, PHA

    synthase has been employed to covalently immobilize

    b-galactosidase on the in vivo PHA granule surface by fusingb-galactosidase to the N-terminus of PHA synthase fromPseudomonas aeruginosa.104 Similarly, both the substrate bind-

    ing domain of PHA depolymerase and the N-terminal domain

    of PhaF phasin or PhaP (PHA granule-associated protein)

    have been used to anchor fusion proteins to PHA micro-

    beads.105 Auto-regulator protein PhaR has been conrmed

    to have two separate domains that bind to DNA and PHB,

    respectively,106 and PhaR can be adsorbed to various types of

    hydrophobic polymers, such as PHB, poly(L-lactide), poly-

    ethylene and polystyrene, mainly by nonspecic hydrophobic

    interactions.107 Banki et al. developed a novel purication

    system for recombinant proteins based on a self-cleaving intein

    fused between phasin and the target protein, and the fusion

    protein was anity bound to in vivo PHB particles produced

    by the cell itself.108 Following the recovery of native PHB

    particles, self-cleavage of the intein resulted in the release of

    puried recombinant proteins. This PHB system pushed

    bio-separation technology several steps forward in the direction

    towards convenience and cheapness.

    It appears that proteins locating on the in vivo PHA granule

    surface may be potential anity tags for protein purication.

    Among them, the nonspecic PHA granule binding protein

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  • phasin as a hydrophobic anity tag appears to be the most

    attractive due to its richness compared with others.

    Backstrom et al. constructed hybrid genes encoding either the

    mouse interleukin-2 (IL2) or the myelin oligodendrocyte glyco-

    protein (MOG) fused via an enterokinase site providing linker

    region to the C-terminus of PhaP, respectively.109 The hybrid

    genes were expressed in PHA-accumulating recombinant

    E. coli. MOG and IL2 fusion proteins were found abundantly

    attached to PHA granules. A more abundant second fusion

    protein of either MOG or IL2 resulted from an additional

    N-terminal fusion, which surprisingly did not interfere with

    attachment to the PHA granule. PHA granules displaying

    either IL2 or MOG were used for FACS using monoclonal

    anti-IL2 or anti-MOG antibodies conjugated to a uorescent

    dye. FACS analysis showed signicant and specic binding of

    respective antibodies. Enterokinase treatment of IL2 displaying

    PHA granules enabled removal of IL2 as monitored by FACS

    analysis. Mice were immunized with either MOG or OVA

    (ovalbumin) and the respective sera were analysed using

    MOG-displaying PHA granules and FACS analysis showed a

    specic and sensitive detection of antigen-specic antibodies

    within a wide dynamic range.109

    Wang et al. developed a novel protein purication method

    based on phasin, a pH-inducible self-cleaving intein and PHA

    nanoparticles.14 Genes for the target proteins to be produced

    and puried were fused to genes of the intein and phasin, and

    the genes were jointly over-expressed in vivo, such as in E. coli.

    The fused proteins containing target protein, intein and phasin

    produced by the recombinant E. coli were released together

    with all other E. coli proteins via a bacterial lysis process, they

    were then adsorbed in vitro to the surfaces of the hydrophobic

    polymer nanoparticles incubated with the cell lysates. The

    nanoparticles attached to the fused proteins were concentrated

    via centrifugation. Then, the reasonably puried target protein

    was released by self-cleavage of the intein and separated with

    nanoparticles by a simple centrifugation process. This system

    was successfully used to produce and purify the enhanced

    green uorescent protein (EGFP), maltase binding protein

    (MBP) and b-galactosidase. This method allows the productionand purication of high value added proteins in a continuous

    way with low cost.14

    A receptor mediated drug delivery system was developed

    based on PhaP.13 The system consists of PHA nanoparticles,

    PhaP and polypeptide or protein ligands fused to PhaP. The

    PHA nanoparticles were used to package mostly hydrophobic

    drugs; PhaP fused with ligands produced by over-expression

    of their corresponding genes in Pichia pastoris or E. coli was

    able to attach to hydrophobic PHA nanoparticles. In the end,

    the ligands were able to pull the PhaPPHA nanoparticles to

    the targeted cells with receptors recognized by the ligands. It

    was found that the receptor mediated drug specic delivery

    system ligandPhaPPHA nanoparticles was taken up by

    macrophages, hepatocellular carcinoma cell BEL7402 in vitro

    and liver, hepatocellular carcinoma cells in vivo, respectively,

    when the ligands were mannosylated human a1-acid glyco-protein (hAGP) and human epidermal growth factor (hEGF),

    respectively, which were able to bind to receptors of

    macrophages or hepatocellular carcinoma cells. The delivery

    system of hEGFPhaPnanoparticles carrying rhodamine B

    isothiocyanate (RBITC) was found to be endocytosed by

    the tumor cells in tumorous model mice. Thus, the ligand

    PhaPPHA specic drug delivery system was proven eective

    both in vitro and in vivo.13

    More applications of PHA granule surface proteins should

    be exploited since similar ideas could be easily developed.

    8. Future development of PHA based industry

    Two aspects should be taken into consideration to help the

    commercial applications of PHA. One is to lower the production

    costs of PHA, and the other is to nd high value added

    applications of PHA. Besides the basic research, many eorts

    have been directed to these two aspects (Table 5).

    The development of low cost PHA production technology

    To lower PHA production costs, genetic engineering technology,

    pathway modication or even synthetic biology approaches

    should be taken to develop super PHA production strains that

    are able to grow to high cell density within a short period of

    time on lower cost substrates under less demanding fermentation

    conditions, such as micro-aerobic conditions.110115 A synthetic

    strain containing the minimum genome could help increase the

    substrate to PHA yield. Simple purication and extraction

    technology employing controllable lysis of high PHA content

    containing bacteria accumulated large PHA granules should

    be developed,116122 such a process can dramatically reduce

    the cost of centrifugation, ltration and extraction as it can be

    coupled with inorganic aqueous treatment.116,117,125 On the

    other hand, the use of simple substrates such as glucose only

    for production of copolymers including PHBV, PHBHHx,

    copolymers of scl- and mcl 3-hydroxyalkanoates, and

    P3HB4HB will reduce the PHA cost attributed to co-substrates

    including propionate, fatty acids or 1,4-butanediol.123,124,130

    PHA produced should have a controllable molecular weight to

    meet various applications.127 Particularly, the use of continuous

    mixed culture fermentation without sterilization is a newly

    developed technology to signicantly lower the PHA production

    cost (K. Johnson et al., ISBP 2008 Lecture). Such a continuous

    process without sterilization avoids the cost of energy

    consumption for sterilization, however, robust PHA production

    strains are needed for this purpose (Table 5). Johnson et al.

    reported the development of a PHB continuous fermentation

    process without sterilization; the process produced 90% PHB

    in the cell dry weight and it lasted for three years without

    troubles. This should be considered as a breakthrough in low

    cost production of PHA.

    Low cost PHA will not only benet the PHA material

    application as bioplastics, but also promote the application

    of PHA as biofuels. This is an area full of promise, since low

    cost PHA could also be obtained from activated sludge

    and waste water fermentation, so it will not run into the

    controversy of food vs. fuel or fuel vs. arable land.10 In a

    not so distant future, plant production of PHA could become

    a reality, as indicated by some promising results.128

    Unusual PHA with special properties

    Unusual PHA containing various functional side groups such

    as double bonds, hydroxyl- and/or carboxyl-groups should be

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  • produced since these PHA have not only intrinsic novel

    properties but also easily-modied side groups which greatly

    expand their applications.

    It is now possible to use low specicity PHA synthases for

    the production of scl- and mcl PHA copolymers through

    screening or molecular evolution,120,122,129,130 and it has

    become a reality to design and produce PHA with the expected

    structures. PHA containing designed functional side groups

    allow chemical modication to change the polymer properties,

    leading to expansion of PHA applications.

    It is now also possible to produce PHA containing various

    blocks like PHB-b-PHV, or PHB-b-PHBV, PHB-b-PHA and

    the similar.131,132 Such block PHA have been found to show

    new properties. More PHB block copolymers are under

    development and they could generate some more unique

    applications.

    PHA with ultra-high molecular weights of over several

    million were reported.127,133 Molecular weights of PHA

    were found to depend on PHA production strains and the

    N-terminus of PHA synthase. Ultra-high molecular weight

    Table 5 Future development for PHA production technology and applications

    Development Technology employed and other issues Ref.

    To lower PHA production costsHigh cell density growth withinshort period of time

    Manipulating quorum sensing pathways. Process control,pathway manipulation

    This lab, 112115

    Controllable lysis of PHAcontaining cells

    Genes related to cell lysis, e.g., lambda lysis factor and lysozyme 116, 117

    Large PHA granules for easyseparation

    Delete phasin led to large in vivo PHA granules 118, 119

    Super high PHA content in cell dryweight

    Delete PhaZ or over-expression of PHA synthesis genesincluding PhaF et al.

    120122

    Micro-aerobic PHA production Employing anaerobic promoter, and/or facultative anaerobicbacteria or other technology including synthetic biology thatturns aerobic processes into micro-aerobic processes

    This lab

    Simple carbon sources for scl- andmcl copolymers

    Application of low specicity PHA synthase, and construction ofpathways to supply mcl PHA monomers from non-fatty acidoxidation pathways

    123, 124, 130

    Enhanced substrates for PHAtransformation eciency

    Delete pathways that aect PHA synthesis, or employ aminimum genome containing cells with an inserted PHA pathway

    This lab

    Inorganic extraction & purication Apply to over 90% PHA containing cells 116, 117, 125Mixed cultures withoutsterilization

    Employ feast and famine selection process to nd robust PHAproduction strain

    Johnson K. ISBP2008 lecture

    Continuous fermentation The use of robust PHA production strains, better undernon-sterilization conditions

    126, Johnson K.ISBP 2008 lecture

    Controllable PHA molecularweight

    Manipulation of the N-terminus of PHA synthase 127

    The use of PHA monomer methylesters as a biofuel or fuel additives

    The development of low cost technology for production of lowcost PHA biofuels or fuel additives

    This lab

    Plants as PHA productionmachines

    Plant molecular biology 128

    PHA with special properties:Novel PHA with unique properties The use of low specicity PHA synthases for production of PHA

    with functional groups for chemical modications, and PHAwith controllable compositions including block PHA copolymers

    120, 122, 129, 130Controllable PHA compositions 131, 132

    Ultra-high PHA molecular weights The use of special strain and mutated PHA synthases 127, 133Block copolymerization of PHA The making of PHA-diols and the block copolymerization with

    other polymers134, 135

    PHA monomers as building blocksfor new polymers

    Copolymerization of PHA monomers with other monomersincluding lactides for the formation of novel copolymers withnew properties

    136, 137 andthis lab

    To develop low cost PHA applications:New PHA processing technology Cost eective processing of PHA as plastic packaging materials 138140PHA blending with low costmaterials

    PHA blending with starch, cellulose et al.

    High value added applicationsPHA as bio-implant materials Further improve the in vivo controllable degradation of PHA

    implants, seek FDA approval for clinical applications9, Tepha Co. Ltd.

    PHA as tissue engineering materials Develop 3-D scaolds as tissue engineering matrices 141PHA monomers and oligomers asnutritional and energy supplements

    Understand the mechanism behind the Ca2+ stimulation eect ofoligomers and monomers of PHA

    6062

    PHA monomers as drugs Study of other non-R3HB monomers as drug candidates 89PHA monomers as ne chemicals Chiral monomers should be exploited as intermediates for chiral

    synthesis8

    PHA as smart materials Tailor-made PHA as shape memory or temperature sensitive gels 142

    This journal is c The Royal Society of Chemistry 2009 Chem. Soc. Rev., 2009, 38, 24342446 | 2443

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  • PHA can be turned into high strength bers for shing nets or

    shing string et al.

    Many studies showed that PHA-diols can be used to

    prepare PHA based block copolymers. These block copoly-

    mers exhibited biocompatibility and temperature sensitive

    behavior,134,135 and they are candidates for applications as

    implant biomaterials and drug delivery matrices.

    Finally, the diverse PHA monomers are a rich pool for

    novel polymer synthesis.136,137 Copolymerization of PHA

    monomers with commercially available polymer monomers

    will generate limitless new copolymers. This is an area that has

    not yet started to attract attention, possibly due to the high

    cost of PHA monomer production. However, a copolymer of

    lactide and 3HB has been recently reported,136,137 signifying

    the start of a PHA monomer based new polymer era.

    The development of low cost PHA applications

    With cost competitive PHA developed, low cost applications

    should also be developed. These include the new processing

    technology that can exploit the existing extruders and other

    molding machines used to make products from common

    plastics like polyethylene and polypropylene.138140 In

    addition, the blending of PHA with cheaper materials like

    starch and cellulose will further reduce the cost without

    the loss of degradability and sustainability (Table 5). In

    addition, PHA can also be used to blend with other low cost

    plastics to form bio-based plastics for improving the cost

    competitiveness.

    To our knowledge, PHA have been successfully turned into

    heat sensitive adhesives, latex and smart gels in the labs.

    Technology should be further developed to produce such

    PHA based bulk materials into commercial products

    (Table 4).

    As indicated (Table 4), many large volume and low value

    applications of PHA have been intensively investigated by the

    materials industries worldwide, and they are approaching step

    by step the reality when large amounts of low cost PHA

    become available in the years ahead.

    High value added applications

    Among the wide variety of applications of PHA, medical

    applications of PHA seemed to be the most economically

    practical area. It is crucial to exploit and develop the

    application of PHA in the medical eld. Almost all PHA

    available in sucient quantities, including PHB, PHBV,

    PHBHHx, P4HB, P3HB4HB and PHO, have been studied

    for bio-implant applications. All of them showed good

    biocompatibility and some biodegradability. Among them,

    P4HB has been approved by the FDA for suture application

    with a trade name TephaFLEX marketed by Tepha Inc., of

    Cambridge, Mass., USA. Future eorts have been directed to

    develop more medical applications for PHA,9 mostly, three

    dimensional scaolds for implant purposes.141

    PHA monomers and oligomers have been found to

    stimulate Ca2+ channels in mammalian cells.60,62,89 They have

    been proposed to be used as drug candidates or nutritional

    and energy supplements based mainly on lab studies. More

    eorts should be directed to understand the mechanisms

    behind this, and more animal studies should also be conducted

    to see the real benets.

    The use of PHA chiral monomers, especially R3HB, as

    chiral intermediates leading to chiral compounds have been

    well documented.8 The large chiral R3HA pool has mostly

    remained untouched. The greater involvement of organic

    chemists could accelerate the expansion of the novel chiral

    compound pool based on PHA chiral monomers.

    In addition, PHA or PHA oligomers block copolymerized

    with other polymers have been found to show some smart

    properties with the possibility for medical applications. This

    should also be taken into consideration for high value added

    uses.142

    Other future applications

    The use of PHA operons expressed in prokaryotes or

    eukaryotes can help enhance the cellular robustness.97100 This

    mechanism should be tested in more industrial microbial

    strains with an aim to select strains with better resistance to

    the stressed conditions and thus enhanced yields of the

    bio-products, including antibiotics, vitamins and amino acids

    et al.

    The amphiphilic proteins on PHA granule surfaces should

    be exploited for more applications in specic drug targeting,

    cell sorting, protein purication and many other applications.

    Conclusions

    Research on the production and application of PHA requires

    interdisciplinary knowledge. Joint eorts by microbiologists,

    geneticists, botanists, chemists, polymer scientists, chemical

    engineers, biotechnologists, medical scientists, government

    agencies and venture capitalists have strongly promoted the

    PHA eld to become an industrial value chain ranging from

    agriculture, fermentation, plastics, packaging, biofuels, ne

    chemicals, and medicine to nutrition. With the availability of

    large amounts of PHA in late 2009, more polymer specialized

    companies will get involved, leading to more applications of

    PHA, and we will see the formation of such a value chain

    accelerate more quickly.

    Acknowledgements

    Over the past many years, I have been supported by the

    Natural Sciences Foundation of China (Grants No.

    30570024/C010103, No. 20334020). In addition, the NSFC

    funding for Distinguished Young Scholar (No. 30225001) also

    contributes to this research. Since 2003, the Li K-Shing

    Foundation has begun to support the systematic PHA

    development. The National High Tech 863 Grants (Project

    No. 2006AA02Z242 and 2006AA020104) and Guangdong

    Provincial Grant for collaboration among industry, university

    and research organization have supported the application

    research on PHA. From 19962002, I was supported by

    P&G based in Cincinnati for the development of PHBHHx

    industrial production technology. Beginning from 2007,

    my lab has been supported by 973 Basic Research Fund

    (Grant No. 2007CB707804).

    2444 | Chem. Soc. Rev., 2009, 38, 24342446 This journal is c The Royal Society of Chemistry 2009

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