INTRODUCTION
⌅Modern agriculture relies on different agrochemicals that have adverse effects on the environment and human health. Given the fact that the current situation is not sustainable, an effective alternative to agrochemicals is needed urgently (Hussain et al., 2017). Microbial fertilizers (biofertilizers) are natural and environmentally safe formulations that are supposed to replace agrochemicals in modern agriculture. These formulations have the potential to stimulate plant growth, assimilate minerals from the soil and increase plant resistance to pathogens. Bacillus subtilis has numerous properties that make it suitable for incorporation into microbial fertilizers with the aim to stimulate plant growth and control the diseases. Due to its non-pathogenicity, pronounced antimicrobial and metabolic activity along with the ability to form endospores, this microorganism has significant potential for wide application in various fields, from medicine and pharmacy to agriculture (Mousivand et al., 2012; Chauhan et al., 2015; Hashem et al., 2019; Malićanin et al., 2020). Important features such as growth on inexpensive carbon sources, low nutritional needs, suitability for genetic manipulation, robustness and resistance while performing large-scale fermentation, make this species very attractive for further analysis and optimization for its final application in biocontrol and plant growth stimulation (Hashem et al., 2019).
Commercial application of microbiological fertilizers depends on the properties of the microbial formulation. A good formulation should be simple, functional and stable, exhibiting great efficiency for a long period of time. Experience from the practice often indicates poor product quality, which brings up the demand to improve biotechnological schemes for the production of such formulations (Vassilev et al., 2015; Stamenković et al., 2018; Stamenkovic-Stojanovic et al., 2019). One of the methods to achieve good-quality microbial products is microencapsulation using spray drying.
Spray drying is a promising microencapsulation technology of microorganisms that increases the resistance and durability of the final product. Owing its popularity to the fact that it enables large production capacities and generous yields, this technique is widespread and applied in various industries (Nedović et al., 2013). The final product has low water activity making it stable and long-lasting. It is also easily stored, transported and manipulated (Nedovic et al., 2011; Huang et al., 2017). Using spray drying technology, a liquid culture is converted into a granular powder by the atomization process. Suspension particles are directed into a steam of hot air (150-200 °C) at high speeds (Huang et al., 2017). Atomized droplets are very small and abundant, thus occupying a very large contact area, which allows a short drying time. Thermal inactivation of the microbial culture is possible, affected mostly by inlet and outlet temperature, air and feed flow rate, drying time and nebulizer pressure (Peighambardoust et al., 2011). Most cells survive if drying is performed at lower temperatures, which in turn results in high residual moisture content and poorer product quality. Hence, the appropriate selection of the feed flow rate and inlet air temperature is crucial for the process success. The optimal values of these variables can be found by trial and error method, or by applying some of the statistical optimization methods (Baş & Boyacı, 2007). The design of experiments combined with response surface methodology and Derringer’s desirability function (Derringer & Suich, 1980) represents trending multiple criteria statistical methodologies which use a minimum number of experiments to obtain precise data and provide complete information about the studied phenomenon (Rodrigues et al., 2019)
Microencapsulation of different B. subtilis isolates have been a subject of a few research groups. So far they examined the influence of different inert ingredients (Yánez-Mendizábal et al., 2012; Meng et al., 2015) on viability and stability of the formulation, with an emphasis on the biocontrol effect. The effect of spray drying conditions have not been investigated yet, neither the possible interaction effects between the factors, which can be very important due to the nature of the process. It remains unknown what spray-drying conditions are required to achieve commercially acceptable products that assert all of the demends of the customers. Is there a compromise solution that will allow high viability along with good powder yield and low moisture content, which in turn is of great importance for the commercialization process? Does the formulation have a phytostimulatory effect in addition to biocontrol properties?
In order to answer the asked questions and fill in the gaps in the previous research, this paper aimed to: (i) apply spray drying to develop novel, comercially competent microbial fertilizers; (ii) asses the individual and combined effects of important spray drying variables using Box-Benkhen experimental design and response surface methodology along with the in depth statistical analysis; (iii) provide statistically significant model equations that simulate the system behaviour; (iv) optimize the spray drying conditions using multiple criteria optimization that will consider both viability and yield, along with moisture content; and (v) examine the shelf-life of the developed product and its phytostimulatory effect on the green pepper seeds
MATERIAL AND METHODS
⌅Microorganism
⌅Bacillus subtilis strain NCIM 2063, obtained from the National Collection of Industrial Microorganisms (NCIM, Pune, India), was used for microencapsulation using spray drying. The bacterial strain was stored at -80 °C in a cryovial and at 4 °C on agar plates. A pre-inoculum was formed from a frozen stock by transferring a single loop to nutrient agar medium (Torlak, Serbia), comprising 0.5% peptone, 0.3% beef extract, 1.5% agar, 0.5% NaCl, and incubating at 37 °C. Erlenmeyer flask containing 300 mL of nutrient broth (Torlak, Serbia) comprising 0.5% peptone, 0.3% beef extract, 0.5% NaCl and 0.03% KH2PO4, was inoculated with a single colony and grown for 24 h in a rotary shaker at 37 °C and 150 rpm to form inoculum, 1% of which was then used for bioreactor inoculation.
Bioreactor cultivation
⌅NCIM 2063 isolate was cultivated in a 2.5 L bioreactor (KLFM, BioEngineering, Wald, Switzerland) containing sterilized DSM medium: nutrient agar, 10% (w/v) KCl, 1.2% (w/v) MgSO4 with addition of 1 mL of filter-sterilized solutions: 1 M Ca(NO3)2, 0.01 M MnCl2 and 1 mM FeSO4. The pH was adjusted by adding 0.01 M NaOH. The culture was grown for 24 h at constant conditions: 33 °C, agitation rate of 440 rpm, airflow rate of 0.3 vvm.
Microencapsulation by spray drying
⌅After 48 h of cultivation, fermentation broth containing B. subtilis NCIM 2063 culture was exposed to a thermal shock for 1 h at 54 °C. Fermentated broth samples were mixed with different amounts of maltodextrin (according to the Box-Benkhen experimental design) and incubated for 10 min to form a homogenous suspension. The initial concentration of viable cells was confirmed by plating on nutrient agar. Each suspension was spray dried in a laboratory scale spray drier Büchi mini B-290 (Flavil, Switzerland). The airflow rate and atomization pressure had constant values of 600 L/h and 0.55 bar, respectively. The inlet temperature and the feed flow rate were set according to the Box-Benkhen experimental design.
Experimental design
⌅The optimization of the spray drying procedure was based on the Box-Benkhen experimental design coupled with response surface technology and Deringer’s desirability function (Derringer & Suich, 1980). Seventeen experiments were conducted in total, with 3 factors at 3 levels. Three independent process variables: maltodextrin concentration (10-50 g/L), inlet air temperature (110-140 °C), and feed flow rate (6-10 mL/min), were determined based on a literature search and preliminary experiments. Dependent variables: moisture content (%), product yield (%), and number of viable cells (CFU/g), were determined in triplicate; mean values were used for the regression analyses using Design Expert software package (Trial version 7.0.0, STAT-EASE Inc., Minneapolis, MN, USA). Experimental data were fitted to the model proposed by the software. Obtained model equation was used to calculate the values predicted by the model. Model adequacy, statistical significance and deviation from the experimental results were evaluated by ANOVA. Optimization of spray drying parameters was performed using Derringer’s desirability function, which is used in complex systems requiring simultaneous optimization of several factors. Based on a optimization criteria it transforms all the system responses on a scale from 0 to 1. By combining individual functions of desirable responses, the total function of preferred responses (D) is calculated with a maximum value ranging from 0 (which is an unwanted answer) to 1 (desired response), and then combined into a mutual response that should have a maximum value under previously defined optimization criteria. As the value of D is approaching 1, the system is being closer to the global optimum value (Derringer & Suich, 1980).
Viability and shelf life
⌅The number of viable microencapsulated cells was determined immediately after spray drying, after six months and one year of storage at room temperature, respectively. Powder formulation (0.1 g) was rehydrated in 0.9% saline solution (NaCl, distilled water), shaken vigorously, and allowed to rehydrate for 12 h. Viable cell concentration was determined using the spread plate method.
Moisture content determination
⌅To determine the moisture content, 2 g of the powder formulation obtained after spray drying was transferred to an aluminum dish and dried at 105 °C to a constant weight. The residual moisture content was calculated according to the following equation:
where wf and wi are weighed mass of the formulation prior to and after drying at 105 ºC, respectively.
Product yield
⌅The yield of the powder formulation obtained after spray drying was calculated using the following equation:
where Wm is the weight of the recovered powder and Wp is the dry weight of the initial suspension in addition to maltodextrin.
Encapsulation efficacy
⌅Encapsulation efficacy was calculated using the following equation:
where Nr is log cfu/mL before spray drying and Nf is log cfu/mL after spray drying.
Characterization and morphology of the formulation
⌅Powder formulation obtained under optimum conditions was analyzed for hygroscopicity, solubility dissolution time and morphology of the microparticles. Hygroscopicity and solubility were determined according to the method described earlier (Bakar et al., 2013), while the dissolution time was calculated as the time required for total dissolution of 1 g of powder in 50 mL distilled water using a magnetic stirrer at 829 rpm (Bhagwat et al., 2020). The morphology of the formulation obtained at optimum conditions was investigated using a JEOL JSM-6610LV scanning electron microscope (30 kV accelerating voltage) with an energy-dispersive X-ray spectrometer (SEM/EDS; XMax Large Area Analytical Silicon Drift connected with INCAEnergy 350 Microanalysis System). Dried powder was coated with a thin gold film at 20 kV voltage to obtain a higher quality secondary electron image for further SEM examination.
Phytostimulatory effect of microencapsulated cells – Pot experiments
⌅Microencapsulated B. subtilis NCIM 2063 formulation was evaluated for promoting growth of green pepper (Capsicum annuum). The experiments were conducted in growth chamber in Leskovac (Serbia) during March-April, 2019. Pepper seeds were disinfected by immersion in a mixture (1:1) of 30% hydrogen peroxide and 70% ethanol for 10 minutes, subsequently washed by immersion in distilled water several times. Seed inoculation was performed by immersion in a resuspended culture of B. subtilis NCIM 2063 with a cell density of 9.1 LOG (CFU/g), after which sowing was performed in previously sterilized plastic pots containing 200 g of dry sterilized fertile chernozem soil. Treatment was performed in 5 replications, 10 pots per replication. The seeds immersed in sterilized water served as a control. The plants were grown for 8 weeks in an incubation chamber at a constant temperature (22 °C), average relative humidity 50-60%, exposed to light of 140 µmol/m2·s wiht a 16 h photoperiod. Vegetative tissue was analyzed for: stem height, root length, number of leaves, leaves and root dry weight and leaf chlorophyll content. Dry weights were determined after drying plant tissues at 65 °C for 24 h, and then at 110 °C until constant weight (Garcia et al., 2011)
The leaf chlorophyll content was determined using the Hiscox & Israelstam´s (1979) method. Briefly, 100 mg of leaves were immersed in 7 mL of DMSO and incubated at 65 °C for 30 min. After adding DMSO to a total volume of 10 mL, 1 mL was transferred to a cuvette and the absorbance was measured at 645 and 663 nm (DMSO blank) using a UV/VIS spectrophotometer (UV/Vis Spectrophotometer - Pye Unicam Ltd, Cambridge England). The chlorophyll content was calculated using Arnon’s equations:
Statistical analyses
⌅All experiments were performed in three parallel replications, and the results were presented as mean value of three repetitions ± standard deviation. The programs Origin 6.0, Excel 2013 and Expert Design 7.0 were used for statistical processing, modeling and graphical analysis of experimental data. Multicriteria optimization was performed by applying the Box-Benkhen experimental design, Response surface methodology and Deringer’s desirability function. The adequacy of the response surface model was assessed using the analysis of variance (ANOVA).