1. Introduction
The transition towards an eco-friendly world has been a topic of discussion for many years. However, efficient strategies must be implemented for a sustainable planet to become a reality in the short term. Based on this, the bioeconomy suggests the development of green technologies for a sustainable production of bioproducts from agricultural wastes, emerging as a sustainable alternative to traditional linear production [
1]. Agricultural wastes are the residues from the growing and processing of raw material such as fruits, vegetables, meat, poultry, dairy products and crops [
2]. They can be solid, liquid or slurries and their characteristics define the type of processing to be applied: energy production (by incineration), composting, animal feed, extraction of added value compound (bio-compounds) or inoculation with appropriate microorganisms (bacteria, yeasts or fungi) to obtain metabolite by biotransformation [
3].
As can be observed, from the vast majority of alternatives that can be applied to the valorization of agro-industrial waste, bioprocesses are part of a promising, profitable, and viable alternative to obtain a wide variety of biobased products. The development of biobased products promotes a sustainable economy without dependence on petrochemical-derived fuels, representing an estimated market volume of USD 429.5 billion in 2024, with a compound annual growth rate (CAGR) of 6.96% (2024-2029) [
4]. Despite the growth trend of this market, it is considered that it has not yet taken off due to the difficulty in: obtaining affordable and sustainable raw materials from reliable sources, ensuring good yields at larger scales, and having a concrete demand from consumers [
5]. Therefore, biotechnological advances are crucial to reducing production costs, improving yields, and making this market attractive to future investors.
A significant contribution that would enhance the biotechnological advances is the implementation of optimization and control strategies for bioprocesses. Process control is a necessary tool to ensure the stability of any system, including bioprocesses, as they are regulated by a complex interaction between the physical, chemical, and biological conditions of the fermentation environment and the biochemical processes that occur within microorganisms [
6]. Bioprocesses can take place in liquid phase (submerged fermentation, SmF) or solid phase (Solid State Fermentation, SSF), with SmF being more widely used because different large-scale operations are easier to carry out in liquids: such as pumping, sterilization and parameter control [
7]. However, SSF has advantages that make it a tempting bioprocess: the use of a small amount of water in the process and high metabolite volumetric productivity [
8].
Lactic acid (LA) is one of the few biobased organic acids that can be produced by fungal SSF from different inexpensive agricultural residues and food waste, such as sugarcane bagasse and juice, corn grain, among others [
9]. Since a few years ago, various biotech companies have been actively investing in the commercialization of bio-based LA, such as: NatureWorks LLC (United States), Corbion-Purac (The Netherlands) and Galactic S.S (Belgium). The most significant demands for LA in the global market come from the food industry, cosmetics, and pharmaceuticals, having gained great importance in recent years its use as a precursor of the biopolymer polylactic acid (PLA), and also its use as a fundamental part of Natural Deep Eutectic Solvents (NADES) being a type of green solvents [
10].
The performance of SSF can be affected by biological factors (type of microorganism, inoculum concentration, type solid substrate type), physicochemical factors (moisture content of the solid bed, pH, temperature, aeration, particle size, gas composition), and mechanical factors (application or absence of mixing and type of bioreactor employed) [
11]. Based on this, it is necessary to ensure that the temperature and moisture of the solid bed are maintained within an operational range that favors the growth of the microorganism and the production of the bioproduct [
12].
Temperature and relative humidity (or moisture of solid substrate) tend to fluctuate significantly in SSF due to the heterogeneity present in the system (characterized by the existence of gas phase, low moisture phase and agro-industrial solid). This complexity adds difficulty to the phenomena of heat and matter transfer, resulting in localized temperature increases and humidity decreases (due to water evaporation and microbial consumption), which negatively influences the growth of the microorganism and the productivity of the bioproduct [
13]. Therefore, matrix water supply should be controlled.
In SSF bioreactors, it is most common to control the conditions of the inlet air, including flow rate, relative humidity (RH), and temperature, to manage the conditions within the solid bed. This can be done in two ways: either controlling the humidity of the air while keeping its temperature constant, or controlling the temperature of the air while keeping its humidity constant [
14]. However, in most fungal SSF studies, the variation of the moisture solid substrate was manually studied, conditioning its humidity at the beginning of fermentation, and then keeping a constant relative humidity airflow [
15,
16,
17,
18,
19].
The air conditioning configurations can vary from simple systems where air enters through a blower, to a system with an air filter, followed by a humidification tank with porous plate (humidifier); to alternatives where humidification columns are used, along with hot and cold water tanks with solenoid valves that allow mixing these water streams to condition the air temperature. The choice between one configuration or another will depend on criteria such as economic performance, capital cost of the devices, and operational costs (blowing the air, heating or cooling the air, producing steam, and heating water) [
14]. Based on this, it would be feasible and simple to use air with a variable relative humidity percentage throughout the SSF.
In this study, we proposed a simple and innovative method aimed at maximizing LA production derived from solid state fermentation of grape stalk (a byproduct of the wine industry in San Juan, Argentina), employing Rhizopus oryzae NCIM 1299 (from Centro de Referencia de Micología, Facultad de Ciencias Bioquímicas y Farmacéuticas, Universidad Nacional de Rosario, Rosario, Argentina).
4. Conclusions
In this work, we presented a dynamic optimization strategy based on Fourier Series and Orthogonal Polynomials, which allowed us to obtain a variable RH profile (smooth, continuous, and differentiable) that maximized LA production. Under experimental conditions, the highest LA production was 0.181 gLA/gGS at 80% RH and 35°C, while applying the variable RH profile resulted in 0.2087 gLA/gGS at the end of the bioprocess, representing a 15.30 % increase. This optimized result could not have been achieved without a methodologically appropriate approach in the experimental stage, as it allowed us to fit mathematical models to the data obtained. The versatility of these models lies in their ability to accurately represent reality, with intuitive and easy to calculate parameters. The use of the hybrid parametric identification technique reduced the convergence time of the Matlab R2015 software compared to traditional methods. The application of second-order polynomials to relate the variation of kinetic parameters to relative humidity was appropriate and confirmed the versatility of polynomials in describing the variability of kinetic parameters in a wide range of biological systems. The strategy proposed in this work is considered to have great potential for application in other bioprocesses, as they are generally nonlinear, highly variable, and complex systems, as is the case of SSF. Based on the results obtained, our group intends to investigate in future work the behavior of fungal bioprocesses for LA production by applying a variable profile of both relative humidity and temperature. The objective will be to correlate the system's response to the time variation of both parameters.