Polyketides serve
as rich source of therapeutically relevant drug
leads. The manipulation of polyketide synthases (PKSs) for generating
derivatives with improved activities usually results in substantially
reduced yields. Growing evidence suggests that type I PKS thioesterase
(TE) domains are key bottlenecks in the biosynthesis of polyene antibiotics,
such as pimaricin and amphotericin, and their unnatural derivatives.
Herein, we elucidate the structure of the 26-membered macrolide-complexed
TE domain from the pimaricin pathway (Pim TE), which specifies a spacious
bifunnel-shaped substrate channel with a highly hydrophobic cleft
proximal to the catalytic triad and a hydrophilic loop I region specific
for the cyclization of amphiphilic polyene macrolide. Notably, the
natural intermediate with C12-COOH is stabilized by a hydrogen-bond
network, as well as by interactions between the polyene moiety and
the hydrophobic cleft. Moreover, the bottleneck in processing the
unnatural intermediate with C12-CH3 is attributed to the
unstable and mismatched docking of the curved substrate in the channel.
Aided by an in vitro assay with a fully elongated
linear polyene intermediate as the substrate, multiple strategies
were adopted, herein, to engineer Pim TE, including introducing H-bond
donors, enhancing hydrophobic interactions, and modifying the catalytic
center. Efficient TE mutations with increased substrate conversion
up to 39.2% in vitro were further conducted in vivo, with a titer increase as high as 37.1% for the
less toxic decarboxylated pimaricin derivatives with C12-CH3. Our work uncovers the mechanism of TE-catalyzed polyene macrolide
formation and highlights TE domains as targets for PKS manipulation
for titer increases in engineered unnatural polyketide derivatives.