A disadvantage of most microbial production processes is the need for sterile techniques. The objective of this study was the development of a robust fungal system allowing monoseptic growth with a minimum of sterile technique in plastic barrels. Selective growth conditions were achieved by mineral salts medium, known for the cultivation of Botrytis cinerea, but containing rapeseed oil instead of glucose as the sole source of carbon and energy. Furthermore, pH 3 was adjusted. A screening of fungi suitable for that system revealed Phialemonium curvatum AW02 isolated from compost. P. curvatum AW02 was superior in comparison with four further fungal isolates because high titers of hydrophilic spores were found in submerged production. Second, a biofilm formation on plastic segments or moving beds made harvesting of the biomass comfortable. Cultivations with volumes of 100 or 350 L showed no contaminations by bacteria when all conditions were controlled. Two independent approaches showed the dependance of growth on lipases in the cultivation system. A B. cinerea strain knocked out in lip1 showed reduced growth in comparison to the wild type because the first catabolic step is the triglyceride hydrolysis. P. curvatum AW02 lipase activity was detected. More than 90% was found to be cell wall associated. Solid shear stress liberated two active proteins showing IEPs of 4.7 or 5.6.

The filamentous fungus Ashbya gossypii is used for riboflavin biosynthesis on an industrial scale, but even the wild type displays overproduction. Because riboflavin overproduction was known to start at the transition between growth and stationary phase, it was suspected that overproduction was induced at low growth rates. However, chemostatic cultivations performed at different growth rates did not result in any detectable riboflavin formation. In this study, we report that it was not the final growth rate that triggered riboflavin overproduction but a decline in growth rate. Therefore, continuous fermenter cultivations with dilution rate shifts were performed. Peaks of riboflavin overproduction were observed in the wild type and in a RIB3placZ reporter strain after downshifts in dilution rate. Accumulation of riboflavin correlated with an increased expression of lacZ reporter activity. The step size of the downshifts corresponded to the peak size of riboflavin formation and reporter activity. Expression of further RIB genes encoding riboflavin biosynthetic enzymes was analyzed by RT-PCR. RIB mRNA levels of the ribulose-5-phosphate branch of the divided riboflavin biosynthesis pathway (RIB3, RIB4, and RIB5) were found to increase in the riboflavin production phase, whereas the RIB2 and RIB7 mRNA levels belonging to the GTP branch remained constant. We propose that a decline in growth rate triggers the increased expression of RIB3, RIB4, and RIB5 resulting in riboflavin overproduction. Because although a reduction in oxygen supply, temperature increase or decrease, or salt stress did affect growth, but neither did lead to riboflavin overproduction nor did induce RIB3 reporter expression, we conclude that declining nutrition must be the stress stimulus. Because about half of the cells in the hyphae of Ashbya gossypii did not accumulate riboflavin, the regulatory response on the cellular level can be estimated to be at least twice as great in comparison to what we detected as overall signals.

The hemiascomycete Ashbya gossypii develops a mycelium. Nutritional stress leads to its differentiation into sporangia. These generate spores. In parallel, the yellow pigment riboflavin is produced. Intracellularly accumulated riboflavin, made visible as a bright green fluorescence, was observed in only 60% of the hyphal cells. For the remaining 40%, it was unclear whether these cells simply export riboflavin or its biosynthesis remains down-regulated in contrast to the accumulating cells. The approach followed in this work was to convert the hyphae into protoplasts by enzymatic degradation of the cell wall. Afterwards, the protoplasts were sorted by fluorescence-activated cell sorting on the basis of riboflavin accumulation. When a reporter strain expressing lacZ under the control of the most important riboflavin biosynthesis promoter, RIB3, was used, green protoplasts were found to have more than tenfold greater reporter activity than hyaline protoplasts. This was true on the basis of total protein as well as on the basis of hexokinase specific activity, a marker for constitutive expression. These results allow the conclusion that hyphal cells of A. gossypii differ in phenotype regarding riboflavin overproduction and accumulation.

To set a benchmark in fungal growth rate, a differential analysis of prototrophic Aspergillus fumigatus AR04 with three ascomycetes applied in > 10 3 t year -1 scale was performed, i.e. Ashbya gosspyii (riboflavin), Aspergillus niger (citric acid) and Aspergillus oryzae (food-processing). While radial colony growth decreased 0.5-fold when A. gossypii was cultivated at 40°C instead of 28°C, A. fumigatus AR04 responded with 1.7-fold faster hyphal growth. A. niger and A. oryzae formed colonies at 40°C, but not at 43°C. Moreover, all A. fumigatus strains tested grew even at 49°C. In chemostat experiments, A. fumigatus AR04 reached steady state at a dilution rate of 0.7 h -1 at 40°C, 120% more than reported for A. gossypii at 28°C. To study mycelial growth rates under unlimited conditions, carbon dioxide increase rates were calculated from concentrations detected online in the exhaust of batch fermentations for 3 h only. All rates calculated suggest that A. fumigatus AR04 approximates Arrhenius' rule when comparing short cultivations at 30°C with those at 40°C. Linearization of the exponential phase and comparison of the slopes revealed an increase to 192% by the 10°C up-shift.

Ashbya gosspyii, a fungus overproducing riboflavin, is applied for > 1000 t/a for two decades. Disadvantages of the overproducer are its need of complex nutrients and a weak pH tolerance. An omnipotent anabolism was shown for Phialemonium curvatum isolated from compost by screening for plant oil degradation on mineral salts medium at pH 3. It can be cultivated in plastic vessels > 100 L with minimal sterile technique. Its potential to convert crude palm oil into organic acids is discussed.