Production of poly-beta-hydroxybutyrate in transformed escherichia coli

Abstract

Methods are provided for enhancing the production of PHB from a transformed E. coli host which includes the genes coding for the PHB biosynthetic pathway. By inserting the genes coding for PHB into a host which includes a lactose utilization system, a low cost minimal medium including whey can be used as the fuel and carbon source for PHB production. A plasmid which codes for the PHB biosynthetic pathway plus four hundred extra bases on either side of the first and last genes in the pathway has been inserted into the host and has been shown to produce a larger amount of PHB accumulation in a shorter period of time than other plasmid constructs. CaCl.sub.2 has been shown to be an effective agglomerating agent for agglomerating PHB which has been produced in a transformed E. coli host.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is related to the following co-pending patent application which is herein incorporated by reference:

"Cloning and Expression in Escherichia coli of the Alcaligenes eutrophus H16 Poly-Beta-Hydroxybutyrate Biosynthetic Pathway", of Douglas E. Dennis, which has Ser. No. 07/362,514 and was filed in the Patent and Trademark Office on Jun. 7, 1989.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is generally related to the production of poly-beta-hydroxybutyrate (PHB) using Escherichia coli (E. coli) which has been genetically transformed by a vector carrying the genes coding for the PHB biosynthetic pathway and, more particularly, to the more efficient production of PHB in transformed E. coli.

2. Description of the Prior Art

PHB is an energy storage material produced by a variety of bacteria in response to environmental stress and is a homopolymer of D-(-)-3-hydroxybutyrate which has properties comparable to polypropylene. Because PHB is biodegradable, there is considerable interest in using PHB for packaging purposes as opposed to other plastic materials in order to reduce the environmental impact of human garbage. PHB also has utility in antibiotics, drug delivery, medical suture and bone replacement applications. PHB is commercially produced from Alcaligenes eutrophus (A. eutrophus) and sold under the tradename Biopol.

As described in the above incorporated patent application and in the article by Slater et al., "Cloning and Expression in Escherichia coli of the Alcaligenes eutrophus H16 Poly-.beta.-Hydroxybutyrate Biosynthetic Pathway", Journal of Bacteriology, Vol. 170, No. 10, Oct. 1988, p. 4431-4436, which is also herein incorporated by reference, it was shown that E. coli could be genetically transformed with genes from A. eutrophus which code for the PHB biosynthetic pathway. E. coli are a far better vehicle for producing PHB than A. eutrophus since more is known about handling the bacteria, E. coli, i.e., E. coli is more easily controlled and manipulated. The transformed E. coli were able to express PHB in relatively large quantities.

Despite PHB's advantages over other materials, its high cost of production has hindered its performance in the market. Currently, PHB is produced in transformed E. coli by growing the E. coli on luria broth (LB) and using glucose as the carbon source. Approximately one third of the production cost of PHB is attributable to the cost of the rich LB medium and the glucose. If a less expensive carbon source could be utilized, the overall cost of PHB production could be significantly reduced. In addition, much of the total cost of PHB production is attributable to purifying the PHB produced in the E. coli. Currently, PHB is purified by centrifugation, followed by mechanical lysis of the cells to release PHB, a high temperature procedure to agglomerate the PHB, and finally a spray drying step to procure the purified granules. If a less expensive method were available for collecting the PHB from the E. coli the overall cost of PHB production could be significantly reduced.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide improved techniques for producing PHB in transformed E. coli.

It is another object of this invention to provide a transformed E. coli strain which can accumulate PHB at higher levels than previous E. coli strains and which can utilize minimal medium containing whey for growing conditions.

It is yet another object of this invention to provide a method of agglomerating PHB granules from lysed E. coli cells using an ionic solution.

According to the invention, a strain of E. coli, i.e., E. coli HMS174, has been transformed by a vector containing a plasmid with the PHB biosynthetic pathway and approximately four hundred extra bases on both the upstream and downstream sides of the pathway. The HMS174 strain of E. coli was chosen because it contains a lactose utilization system and is recombination deficient so that a plasmid containing lactose genetic regions will not recombine and make the construct unstable. The lactose utilization system present in E. coli HMS174 has allowed whey to be used as a carbon source for the production of PHB. Whey is a waste product from cheese processing and is very inexpensive. Experiments have been performed which show that the strain of transformed E. coli grows in minimal medium containing whey and has an average yield of PHB of approximately 85% (PHB dry weight/total cell dry weight).

In addition, experiments have been conducted which show that PHB produced in transformed E. coli may be agglomerated with various ionic solutions. To retrieve purified PHB in large quantities, the transformed E. coli cells are first lysed by mechanical or physical means, such as by sonication, or by genetic means. Then, the cells are incubated in an ionic solution, such as 10 millimolar (mM) calcium chloride (CaCl.sub.2), which agglomerates the PHB granules. Finally, the agglomerates are centrifuged from the culture at low speed. Experiments show that nearly all (100%) of the PHB in the culture is agglomerated and recovered by this process. The results are especially exciting since the same type of agglomeration is not possible for retrieving PHB from A. eutrophus.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, aspects and advantages will be better understood from the following detailed description of the preferred embodiments of the invention with reference to the drawings, in which:

FIG. 1 is a line graph showing PHB accumulation versus time for a variety of E. coli clones containing different plasmid constructs;

FIGS. 2a and 2b are bar graphs showing the accumulation of PHB produced by transformed E. coli using minimal medium and whey;

FIG. 3 is a bar graph showing the percentage of PHB agglomeration using CaCl.sub.2 ;

FIG. 4 is a line graph showing the PHB agglomerations versus time where PHB is accumulated in the presence of radiolabelled glucose and then subjected to the agglomeration procedure; and

FIG. 5 is a bar graph showing the contrasting effects of glass milk and calcium on PHB agglomeration.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

Referring now to the drawings, and more particularly to FIG. 1, it is shown that the E. coli strain HMS174 containing the plasmid p4A accumulates a greater percentage of PHB in a shorter period of time than other E. coli clones containing different plasmid constructs. The E. coli strain HMS174 is available from the Yale E. coli Stock Center, Dept. of Biology, 355 OML, Yale University, P.O. Box 6666, New Haven, Conn. 06511-7444, Barbara Bachman curator. The p4A plasmid carries the PHB biosynthetic pathway and approximately four hundred extra bases to the upstream and downstream sides of the PHB biosynthetic pathway on the vector pTZ-18U. The vector pTZ-18U is available from United States Biochemicals. MSA carries the PHB biosynthetic pathway on the vector pTZ-18U and the E-lysis gene from phage phi X 174 on another compatible plasmid. MSA differs from p4A in that it has approximately four hundred extra bases on the upstream side of the PHB biosynthetic pathway (i.e., the PHB biosynthetic pathway is cloned into pTZ-18U to create pTZ-18U--PHB called "MSA", and p4A is pTZ-18U-PHB less four hundred bases on the upstream side of the PHB biosynthetic pathway). GEM carries the PHB biosynthetic pathway on the vector pGEM-7F+ which is available from the Promega Corporation.

The p4A, pTZ-18U--PHB (MSA), and pGEM7f-PHB(GEM) clones were all constructed from the E. coli clone harboring the PHB biosynthetic pathway discussed in the above-referenced and incorporated co-pending patent application and journal article using conventional molecular cloning techniques. As was disclosed in the patent application and journal article, the PHB biosynthetic pathway can be isolated from A. eutrophusand expressed in E. coli. The PHB biosynthetic pathway is approximately five kilobases in length and contains bases coding for .beta.-ketothiolase, NADP-linked acetoacetyl-coenzyme A (CoA) reductase, and PHB synthetase. FIG. 1 shows that the MSA and GEM clones do not produce as much PHB as the p4A clone.

E. coli HMS174 was chosen as the host because it contains a lactose utilization system and it is recombination deficient. Recombination deficiency assures that a plasmid containing lactose genetic regions will not recombine and make the construct unstable. As will be described below, the presence of the lactose utilization system in HMS174 allows whey, a cheese manufacturing waste product whose major component is lactose, to be used as the carbon source for PHB production. In making the transformed E. coli strain, the plasmid p4A, which is the PHB biosynthetic pathway plus four hundred bases upstream and downstream of the PHB biosynthetic pathway cloned into the United States Biochemical vector pTZ-18U, is electroplated into the E. coli HMS174. A strain of the E. coli harboring the p4A plasmid has been deposited with the American Type Culture Collection of 12301 Parklawn Drive, Rockville, Md. on May 23, 1990, and bears deposit number: 68329 designated as E. coli HMS174/p4A (PHB 90) and deposited in accordance with the requirements of the Budapest Treaty.

Experiments were performed which showed that the HMS174 strain of E. coli which had been transformed with the p4A plasmid could be grown on minimal medium containing whey. The minimal medium used was M9 minimal medium which is described in most microbiological biology texts. Table 1 lists the formulation for a 5X concentrate of M9 minimal medium where each of the listed components is added to a liter flask and water is added to one liter.

TABLE 1______________________________________5X M9 MINIMAL MEDIUM FORMULATION______________________________________ 30 g Na.sub.2 HPO.sub.4 15 g KH.sub.2 PO.sub.4 5 g NH.sub.4 Cl 2.5 g NaCl______________________________________ Whey was purchased from Sigma chemicals as a powder of bovine whey, and was made by stirring 20 grams of whey in water that had a final volume of 100 ml. Stirring took place with mild heating for approximately 30 minutes. This solution was then autoclaved and particulates that precipitated during centrifugation were pelleted by centrifugation at 10,000.times.g for 10 min. The remaining supernate was used as the whey carbon source.

In the experiments, the HMS174 E. coli strain containing the plasmid p4A was inoculated from a plate culture into 50 ml of M9 minimal medium+whey solution. Table 2 lists the formulation for 50 ml of minimal medium containing whey at a final concentration of 8%.

TABLE 2______________________________________MINIMAL MEDIUM + WHEY FOR PHB PRODUCTION______________________________________10 ml 5X M9 medium20 ml ddH.sub.2 O (double distilled water)50 .mu.l 1 M MgSO.sub.45 .mu.l 0.5% Thiamine250 .mu.l 20% casamino acids20 ml 20% whey solution______________________________________

The inoculated culture was grown at 37.degree. C. for 48 hours in an orbital incubator shaker at 300 rpm in a 250 ml baffled flask. After the 48 hour incubation time, the culture was stopped and the cells were harvested. Gas chromatography was used to analyze the PHB content.

FIGS. 2a and 2b respectively show the percentage of PHB accumulated in the cells, expressed as PHB weight per cell divided by the total weight of the cell, and the yield of PHB in the cells, expressed as the total PHB made in mg/ml, for differing concentrations of whey in solution with the minimal medium. FIGS. 2a and 2b show that even with very low concentrations of whey, i.e., 2% in solution, high concentrations of PHB accumulation (i.e., greater than 90%) and high yields of PHB (i.e., approximately 10 mg/ml). While FIGS. 2a and 2b show that medium with higher concentrations of whey tended to produce greater concentrations and yields of PHB, it was noted that after the whey concentration exceeds 8%, PHB production begins to fall.

In the above experiments, PHB production was analyzed after forty eight hours of incubation; however, it should be noted that significant PHB production was observed after twenty four hours of incubation. In addition, it is anticipated that the relative concentrations of the Na.sub.2 HPO.sub.4, KH.sub.2 PO.sub.4, NH.sub.4 Cl , and NaCl in the 5X minimal medium formulation and the relative concentrations of the 5X minimal medium, double distilled water, MgSO.sub.4, Thiamine, casamino acids, and whey solution could be varied while still allowing production of PHB in a transformed E. coli host having a lactose utilization system.

Utilizing whey as the carbon source for the production of PHB, where the whey is present in minimal medium, is expected to result in considerable cost savings over the prior art practice of using rich medium with glucose for producing PHB. The prior art transformed E. coli cells which had plasmids coding for the PHB biosynthetic pathway, which were discussed in the co-pending patent application and journal article, could not be grown using whey as the carbon source since those bacteria did not have a lactose utilization system present therein. PHB cannot be produced using whey as its carbon source in the native host, Alcaligenes eutrophus, because that bacteria also lacks a lactose utilization system. In addition, as shown in FIG. 1, transforming a particular E. coli host, HMS174, with a particular plasmid, p4A, allows the production of PHB at much higher percentages than when the E. coli is transformed with a different vector which also codes for the PHB biosynthetic pathway.

Because the PHB is being produced in E. coli, rather than its native host (A. eutrophus), the applicant believed that the PHB polymer produced by the transformed E. coli might have different physical properties from PHB produced in A. eutrophus. In particular, the applicant conducted experiments to determine if PHB produced by a transformed E. coli could be agglomerated by various ionic solutions. In the experiments, PHB was produced in transformed E. coli as discussed in the above-incorporated co-pending patent application and journal article. Briefly, a PHB-producing strain is grown in Luria broth (LB) containing 1% glucose for 24 hours at 37.degree. C. in a shake flask culture. The cells are pelleted by centrifugation (2,000.times.g for 5 min) and then resuspended in a volume of water equal to the original culture. The cells were then lysed by sonication and various ionic reagents were added to the solution. Table 3 shows the aggregative effect on PHB produced in transformed E. coli by various ionic solutions.

TABLE 3______________________________________AGGREGATION OFPHB BY VARIOUS IONIC SOLUTIONSSolution* Degree of Aggregation**______________________________________KH.sub.2 PO.sub.4 ++NaCl +CsCl -MgSO.sub.4 +++K.sub.2 HPO.sub.4 +MgCl.sub.2 ++++(NH.sub.4).sub.2 HPO.sub.4 +MgOAc ++++NaOAc ++KCl -KOAc -CaCl.sub.2 ++++(NH.sub.4)OAc -______________________________________ *All solutions were at a final concentration of 1M. **Agglomeration was subjectively graded using micrographs of each aggregate. "++++" signifies the best agglomeration and "+" signifies the lowest amount of agglomeration. "-" signifies no agglomeration.

Table 3 shows that several ionic solutions cause PHB produced in transformed E. coli to agglomerate. The best agglomerating agent was CaCl.sub.2 based on a subjective judgement concerning the speed and size of the agglomerates. The agglomeration effect of CaCl.sub.2 on PHB produced in transformed E. coli is especially interesting since CaCl.sub.2 does not cause PHB produced in its native A. eutrophus to agglomerate (i.e., an experiment was performed where PHB granules were obtained from lysed Alcaligenes H16 eutrophus and subjected to calcium chloride wherein no agglomeration was observed).

Experiments were conducted to determine the ideal concentration of CaCl.sub.2 to use for agglomerating PHB. In the experiments, the transformed E. coli cells were prepared and lysed as described above, then the solutions were brought to different mM CaCl.sub.2 concentrations using a 1M stock CaCl.sub.2 solution. With low concentrations of CaCl.sub.2, e.g., 1 mM, very long incubation times were required for PHB granules to agglomerate and only small agglomerates were produced. With high concentrations of CaCl.sub.2, e.g., 100 mM and above, agglomeration occurred almost instantaneously and resulted in large "snowflake"-like particles that fell to the bottom of the tube. However, the agglomerates achieved with high concentrations of CaCl.sub.2 appeared to have large amounts of cell debris. Therefore, high concentrations of CaCl.sub.2 are not desirable for agglomeration. When medium concentrations of CaCl.sub.2 were used, e.g., 5 mM to 30 mM, agglomeration of medium sized pellets occurred within a short incubation period of 5 to 15 minutes. Use of 10 mM CaCl.sub.2 was determined to produce the best agglomeration results in terms of speed and size of agglomerate formation.

Experiments were performed to determine the percentage of PHB agglomerated by CaCl.sub.2 versus the percentage of PHB left in solution. In the experiments, a PHB-producing strain of E. coli was grown in Luria broth containing 1% radio labelled glucose for 24 hours at 37.degree. C. in a shake flask culture. The cells were pelleted by centrifugation (2,000.times.g for 5 min) and then resuspended in a volume of water equal to the original culture. The cells were then lysed by sonication and then the solution was brought to 10 mM by the addition of a 1M calcium chloride stock. The tube was incubated 10 min at room temperature and then centrifuged at 400.times.g for 2 min. The agglomerated PHB granules pelleted, while much of the cell debris stayed in the supernate. The supernatant was then aspirated. To determine the distribution of PHB in the pellet and supernatant, the pellet and supernatant were measured using either capillary gas chromatography or liquid scintillation counting.

FIG. 3 shows that nearly all (100%) of the PHB in the culture was agglomerated and recovered by the above process. In this experiment, the amount of PHB was measured only by gas capillary chromatography. This experiment was done at several cell volumes to determine if the volume of the flask influenced the degree of agglomeration and it was found that in all volumes nearly all of the PHB was agglomerated and subsequently pelleted by centrifugation.

FIG. 4 shows that it is extremely important that the culture be allowed sufficient time for agglomeration to occur, otherwise the yield is reduced. Rather than allowing a full ten minute incubation time after the solution was adjusted to 10 mM CaCl.sub.2, the pellet and supernatant fractions were counted at two minute timed intervals after the adjustment. FIG. 4 shows that during the first few minutes after adding CaCl.sub.2 the amount of PHB present in the supernatant is actually greater than in the pellet. However, after eight minutes (where the amount of PHB measured in the pellet begins to level off), the amount of PHB in the pellet is far greater than in the supernatant fraction. It should be noted at this point that this experiment measures radioactive .sup.14 Carbon, most of which is incorporated into PHB as .sup.14 C-glucose (approximately 60% is incorporated), but some of which is present as soluble material. Therefore, even though nearly all of the PHB is precipitated, there is still a large number of counts in the superhate that is due to the soluble radioactive glucose.

FIG. 5 shows that agglomeration of PHB can be enhanced by the addition of nucleating agents such as glass milk available from Bio 101. In FIG. 5, the counts per minute (CPM) of the pellet and supernatant fractions are displayed where "+gm, +Ca" indicates PHB agglomeration in the presence of glass milk and 10 mM CaCl.sub.2, "-gm" indicates PHB agglomeration in the presence of 10 mM CaCl.sub.2 without glass milk, "-gm, -Ca" indicates PHB agglomeration in the absence of glass milk and CaCl.sub.2, and "-Ca" indicates PHB agglomeration in the presence of glass milk and in the absence of CaCl.sub.2. From FIG. 5, it can be seen that the enhancement of agglomeration by the addition of nucleating agents is not very large; therefore, larger production schemes may not be greatly benefitted by the use of such agents.

While the invention has been described in terms of its preferred embodiments where a strain of transformed E. coli has been created which can accumulate larger quantities of PHB while using an inexpensive carbon source such as whey for PHB production and an ionic solution such as CaCl.sub.2 can be used to agglomerate PHB, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.

Claims

1. An Escherichia coli bacterial host transformed by a vector consisting essentially of a deoxyribonucleic acid sequence encoding the poly-beta-hydroxybutyrate biosynthetic pathway of Alcaligenes eutrophus wherein the bacterial host has a lactose utilization system and grows in minimal medium containing whey and wherein the bacterial host is Escherichia coli strain ATCC 68329.

2. A method for producing poly-beta-hydroxybutrate, comprising the steps of:

providing a culture of the bacterial host of claim 1;

growing said culture in a growth medium comprising minimal medium and whey for a period greater than twenty four hours, said bacterial host producing intra-cellular poly-beta-hydroxybutyrate;

lysing said bacterial host in said culture to release said poly-betahydroxybutyrate; and

collecting said poly-beta-hydroxybutyrate.

3. The method as recited in claim 2 in which said Escherichia coli bacterial host is grown in a growth medium comprising:

0. 6% Na.sub.2 HPO.sub.4 ;

0.3% KH.sub.2 PO.sub.4 ;

0.1% ammonium chloride;

0.05% sodium chloride;

58.84% water;

0.012% magnesium sulfate;

0.0005% thiamine;

0.01% casamino acids; and,

40% whey solution.

4. The method as recited in claim 2 wherein said minimal medium is approximately twenty percent of said growth medium, said whey is approximately forty percent of said growth medium, and water is approximately forty percent of said growth medium.

5. A method as recited in claim 2 wherein said step of collecting includes the step of exposing said released poly-beta-hydroxybutyrate to an ionic reagent selected from the group consisting of magnesium sulfate, magnesium chloride, magnesium acetate, and calcium chloride, said ionic reagent being of sufficient concentration to agglomerate said poly-beta-hydroxybutyrate.

6. A method as recited in claim 5 wherein said ionic reagent is calcium chloride at a concentration ranging between one molar and one millimolar.

7. A method as recited in claim 6 wherein said calcium chloride has a concentration of approximately ten millimolar.

8. A method for agglomerating poly-beta-hydroxybutyrate which has been intracellularly produced in a culture of Escherichia coli (strain ATCC 68329) bacterial host which has been transformed by a vector the vector containing a deoxyribonucleic acid sequence coding for the poly-beta-hydroxybutyrate biosynthetic pathway from Alcaligenes eutrophus, comprising the steps of:

lysing said bacterial hosts to release said poly-beta-hydroxybutyrate; and

adding to said released poly-beta-hydroxybutyrate a sufficient quantity of an ionic reagent selected from the group consisting of magnesium sulfate, magnesium chloride, magnesium acetate and calcium chloride, said sufficient quantity of said ionic reagent agglomerating granules of said poly-beta-hydroxybutyrate.

9. A method as recited in claim 8 wherein said ionic reagent is calcium chloride.

10. A method as recited in claim 8 wherein said calcium chloride is present at a concentration ranging between one molar and one millimolar.

11. A method as recited in claim 10 wherein said calcium chloride is present at a concentration of approximately 10 mM.

12. A plasmid designated as p4A and deposited with the American Type Culture Collection in Escherichia coli strain HMS 174 under accession number 68329.

13. The method recited in claim 8 further comprising the step of adding a nucleating agent to said quantity of said ionic reagent.

14. A method as recited in claim 10 wherein said calcium chloride is present at a concentration ranging from about 5 mM to about 30 mM.

15. A plasmid designated as pTZ-18U PHB and deposited with the American Type Culture Collection in Escherichia coli strain HMS174 under accession number 69064.