1.1 Cellulose
Cellulose is a linear homopolysaccharide is composed of β-D-glucopyranose units that are linked by β-1, 4 glycosidic bonds (Raj et al., 2021). It is a polysaccharide consisting of 15,000 D- glucose monomers. Plants and bacteria are the primary sources of cellulose extraction (Rajeshkumar et al., 2021). Extraction of cellulose from plants remains challenging. To extract cellulose efficiently, the removal of other components such as lignin and hemicelluloses must be properly managed. Delignification and hemicellulose removal are required during the extraction of cellulose from any plant or agro waste. Bleaching is done to obtain bleached cellulose material (Gallegos et al., 2016).
1.2 Bacterial cellulose
In addition to plant cellulose, certain gram-negative bacteria possess the ability to produce cellulose (Iqbal et al., 2015). Bacterial cellulose (BC) is considered pure cellulose and is gaining significance in various industries such as paper, textiles, and leather (Iqbal et al., 2015). Various bacteria, including Gluconacetobacter, Aerobacter, Rhizobium, Sarcina, Azotobacter, Agrobacterium, Pseudomonas, and Alcaligenes, can synthesize BC. Among these, Gluconacetobacter xylinus, a Gram-negative, rod-shaped bacterium, has been the earliest and most extensively studied microorganism responsible for BC production, initially discovered by Brown in 1886 (Donini et al., 2010).
BC is composed of ribbon-like cellulose nanofibers (Fig. 1.1), that weave together to form a 3D reticulated network (Ruka et al., 2010). The structure of BC has both crystalline and non- crystalline areas, similar to that of plant cellulose, having up to 90% crystallinity (Wang et al., 2019; Sijabat et al., 2020). Additionally, it exhibits elevated levels of polymerization, mechanical strength, water retention capacity, chemical stability, and adaptability to biological environments (Watanabe et al., 1998). Bacterial cellulose demonstrates environmental friendliness and sustainability. It is biodegradable and has no deleterious or allergic side effects (Yim et al., 2017).
1.3 SCOBY symbiotic culture of bacteria and yeast
The symbiotic culture of bacteria and yeast, known as SCOBY, is composed of a diverse community of bacteria and yeast strains (Teoh et al., 2004). The most crucial bacteria in SCOBY are Gram-negative species such as Acetobacter and Gluconacetobacter, which play a vital role in the fermentation process responsible for producing kombucha and bacterial cellulose (Esa et al., 2014).
In the SCOBY, acetic acid bacteria and yeast work in symbiosis to enhance cellulose production (Dima et al., 2017). Yeasts in SCOBY possess invertase enzymes, which break down sucrose into reducing sugars, releasing monosaccharides into the medium. These monosaccharides serve as a carbon source for the bacteria. Additionally, the bacteria utilize glucose as a carbon source to produce bacterial cellulose. Simultaneously, the yeast produces ethanol, which promotes the bacterial cellulose synthase process, ultimately leading to the production of a bacterial cellulose film (Hamed et al., 2023). This intricate interplay between bacteria and yeast is essential for successful fermentation and cellulose production in SCOBY cultures.
1.4 Kombucha
Kombucha, a popular fermented tea drink enjoyed globally, originated in China and later spread to Russia and beyond. Initially, microbiologists categorized Kombucha as a type of lichen because it involves a symbiotic relationship between fungi and acetic acid bacteria (AAB). However, unlike typical lichens, which are symbiotic associations of algae and fungi and rely on light for photosynthesis, Kombucha thrives in darkness (Brown et al., 1976). The Kombucha culture initially resembles a white, rubbery pancake and undergoes changes in appearance throughout the fermentation process. Initially, it has a creamy white color, but when brewed with black tea, the culture darkens due to the presence of tannins in the tea.
During Kombucha fermentation, microorganisms utilize sucrose as the primary carbon source, while nitrogen is derived from the tea extract. In the presence of oxygen, the SCOBY produces organic acids, carbon dioxide, and a dense cellulosic biofilm composed of cellulose. This biofilm thickens as fermentation progresses, often forming multiple layers resembling pancakes (McNamara et al., 2015).
1.5 Parameters affecting the growth of Bacterial Cellulose
1.5.1 pH
SCOBY typically thrives in an acidic environment with a pH range of about 2.5–4.5. This low pH is primarily due to the production of acetic acid and lactic acid during the fermentation process. The acidity of the environment helps create a suitable and protective habitat for the bacteria and yeast within the SCOBY community (Lee et al., 2014).
1.5.2 Temperature
Temperature is another critical parameter that influences the adaptation patterns of microorganisms for survival. A temperature range of 25 to 30°C is optimal to produce BC by certain Komagataeibacter species, while the optimum temperature for BC production by Acetobacter xylinum is 28°C (Wang et al., 2018). Temperature regulation is crucial for achieving efficient BC production in these bacterial cultures.
During the fermentation process, a biofilm often thickens and forms a matrix known as a pellicle. This pellicle's primary role is to protect the SCOBY (Symbiotic Culture of Bacteria and Yeast) from potential competitors or contaminants. Typically, after the Kombucha manufacturing process is completed, this biofilm is considered a byproduct and is commonly discarded (Borzani et al., 1995).
However, due to its composition primarily consisting of cellulose, this discarded pellicle has proven to be a valuable resource for various innovative applications. Despite being typically discarded as a byproduct of Kombucha production, the cellulose-rich biofilm pellicle offers a valuable resource for various industries seeking innovative and sustainable materials for a range of applications (Vandamme et al., 1998).
1.6 Raw material for Bacterial Cellulose production
Waste materials pose significant economic and environmental threats to the world. Food waste is a major concern, as food manufacturers and processors generate millions of tons annually, much of which could be prevented or recycled. Approximately one-third of all food produced worldwide is lost or wasted, leading to direct product loss and the discarding of valuable byproducts rich in sugars and other food ingredients by various industries. This not only impacts economies but also creates conditions favorable for microbial growth, posing environmental and health risks. In addition to reducing waste, it’s crucial to explore opportunities for recycling and converting waste into valuable products (Millati et al., 2019).
Globally, there are about 2 billion tons of agricultural waste that accumulates every year (Pakistan Sugar Mills Association 2021). Pakistan is ranked fifth among all sugar-producing countries and in 2022 (Knoema 2023), it produced 88 million tons of sugar cane (Afghan et al., 2023). Sugarcane bagasse is highly valued by sugar producers as a primary feedstock source for bioenergy and biofuel production due to its rich carbon content (Jozala et al., 2015). Additionally, it has the potential to be used in the production of bacterial cellulose.
For over a century, there has been considerable interest in developing cost-effective methods for producing BC. The main challenges have been the expense of commonly used culture media and the slow production processes, hindering large-scale industrial production. Various approaches, including novel synthetic methods and the use of different bioreactors, have been explored to improve BC production. Despite some success, achieving economically viable BC production remains elusive. Efforts have focused on using inexpensive and waste sources such fruit juices, bagasse, molasses, and industrial wastes. While these alternatives can reduce production costs, challenges like purification expenses, environmental concerns, and subpar physiological qualities persist. Finding affordable materials with easy processing methods for high-quality BC production remains a crucial endeavor (Costa et al., 2017).
This research aimed to synthesize bacterial cellulose using waste materials such as carbon and nitrogen sources. Furthermore, bacterial cellulose production was qualitatively and quantitatively estimated. This work eventually will be helpful to produce a sustainable and cost-effective product and will additionally reduce food waste.