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In order to overproduce bioinsecticides production by a sporeless Bacillus thuringiensis strain, an optimal composition of a cheap medium was defined using a response surface methodology. In a first step, a Plackett-Burman design used to evaluate the effects of eight medium components on delta-endotoxin production showed that starch, soya bean and sodium chloride exhibited significant effects on bioinsecticides production. In a second step, these parameters were selected for further optimisation by central composite design. The obtained results revealed that the optimum culture medium for delta-endotoxin production consists of 30 g L(-1) starch, 30 g L(-1) soya bean and 9 g L(-1) sodium chloride. When compared to the basal production medium, an improvement in delta-endotoxin production up to 50% was noted. Moreover, relative toxin yield of sporeless Bacillus thuringiensis S22 was improved markedly by using optimised cheap medium (148.5 mg delta-endotoxins per g starch) when compared to the yield obtained in the basal medium (94.46 mg delta-endotoxins per g starch). Therefore, the use of optimised culture cheap medium appeared to be a good alternative for a low cost production of sporeless Bacillus thuringiensis bioinsecticides at industrial scale which is of great importance in practical point of view.

A multiple linear regression analyses were performed to screen for the significant factors simultaneously influencing production of deltaendotoxin, proteolytic activities and spore formation by a Bacillus thuringiensis kurstaki strain. Investigated factors included: pH of the medium, available oxygen and inoculum size. It was observed that oxygen availability was the most influencing setting on both deltaendotoxins production and spores counts, followed by initial pH of the medium and inoculum size. On other hand, pH of medium was found to be the most significant parameter for proteolytic activity, followed by inoculum size and dissolved oxygen. Our results suggested that the first order with two-factor interaction model seemed to be more satisfactory than simple first order model for optimization of delta-endotoxin overproduction. The coefficients of determination (R') indicated a better adequacy of the second order models to justify the obtained data. Based on results, relationships between delta-endotoxins production, proteolytic activities and spores counts were established. Our results can help to balance delta-endotoxins production and its stability.

Statistical experimental designs, involving a Plackett-Burman design followed by a rotatable central composite design were used to optimize the culture medium constituents for Bacillus thuringiensis bioinsecticide production. This was carried out by using firstly an asporogenic strain and extrapolated to some sporeless and sporulating strains. Initial screening of production parameters was performed and the variables with statistically significant effects on delta-endotoxin production were identified: glucose, glycerol, yeast extract and MnSO(4). These variables were selected for further optimization by response surface methodology. The obtained results revealed that the optimum culture medium for delta-endotoxin production consists of 22.5 g/l of glucose, 4.8g/l of glycerol, 5.8 g/l of yeast extract and 0.008 g/l of MnSO(4). Under these conditions, delta-endotoxin production was 2,130 and 2,260 mg/l into 250 and 1,000 ml flask respectively, which represent more than 38% improvement in toxin production over the basal medium (1,636 mg/l). Such medium composition was shown to be suitable for overproducing delta-endotoxins by sporeless and sporulating strains., (Copyright © 2011 Elsevier B.V. All rights reserved.)

The use of bioinsecticides, particularly those produced by sporeless Bacillus thuringiensis strains, has been shown to be a good alternative in pest management. Two types of sporeless mutants were distinguished. The asporogenic mutants which completely lack spores produce a regular bipyramidal crystal inclusion. The oligosporogenic mutants kept the ability to produce insecticidal crystal proteins. However, sporulation in such mutants was not totally blocked and very few of them could still produce spores. In order to improve bioinsecticides production, adaptation of sporeless strains to heat shock and osmotic stress was investigated. Delta-endotoxin production by 78% of sporeless mutants was significantly improved by osmotic stress with an overproduction of about 17%, compared to the wild strain BNS3. However, toxin production was improved by only 21% of mutants after heat shock, in low cost medium. The statistical analysis proved that delta-endotoxin production, cell growth, and spore formation of asporogenic and oligosporogenic mutants depended on the type of applied stress. Each strain has an important potential when applying the adequate stress. Moreover, adaptation of sporeless mutants to NaCl may allow the substitution of all minerals of the medium by diluted sea water which appeared to be a good alternative for the economic production of bioinsecticides at industrial scale which is of great importance from the practical point of view.

Chitinases have been successfully used in combination with Bacillus thuringiensis delta-endotoxins forming crystals in order to enhance their insecticidal activities. In this context, we opted for promoting the chitinase integration into these crystals. Thus, we engineered, for the first time, a fusion protein (CDF) consisting of the chitinase Chi255 and the carboxy-terminal half of Cry1Ac, both from B. thuringiensis subsp. kurstaki. The constructed transcriptional fusion (chi255Δsp-CTcry1Ac) was cloned into a shuttle vector (Escherichia coli/B. thuringiensis) downstream the sporulation-dependent promoters BtI-BtII and upstream the cry1Ac transcription terminator. The resulting plasmid, named pF, was transferred by electroporation to crystalliferous B. thuringiensis strain BNS3 and acrystalliferous strain BNS3Cry-. The functionality of the chimerical chitinase was demonstrated by an improvement of the relative chitinolytic activity of the recombinant strain BNS3/pF by 2.5 folds. Western blot analyses showed that, despite of the instability of CDF when expressed in the acrystalliferous strain, the C-terminal half of Cry1Ac succeeded to allow the integration of the chimerical chitinase into the crystal of BNS3. The recombinant strain BNS3/pF (LC(50) = 144.06 μg g(-1)) was 1.5 times more active against Ephestia kuehniella larvae than the wild strain (LC(50) = 212.10 μg g(-1)).

Asporogenic and oligosporogenic Bacillus thuringiensis mutants having the ability to overproduce insecticidal crystal protein were generated by using nitrous acid (50 mg/ml), as chemical mutagenic agent. Insecticidal crystal proteins produced by asporogenic mutants remained encapsulated within the cells. Delta-endotoxin production by most of mutants was improved compared to the corresponding wild strains BNS3 and a mutant M26. The overproduction by asporogenic and oligosporogenic mutants was attributed to defect in genes involved in sporulation and to random mutations affecting cell metabolism at different pathways and delta-endotoxin synthesis. Sporeless bioinsecticides could be developed based on stable and environmentally safe Bacillus thuringiensis mutants.

The acquisition of the erythromycin resistance by Bacillus thuringiensis kurstaki improved yields of delta-endotoxins in sporulating cells ranging from 134 to 215%. Resistance to erythromycin decreased the final spore count by at least 50%. Consequently, erythromycin resistance is an efficient tool for the improvement of bioinsecticides yields with a high ratio of delta-endotoxins to spores.

Bacillus thuringiensisis a Gram positive bacterium that produces an insecticidal crystalline protein making it one of the most important biocontrol agents for pest management. Bioinsecticides based onB. thuringiensiswere produced by fermentation processes in liquid media. Cultural conditions controlling proteolytic activities in different culture media were investigated to study the possible correlations betweenB. thuringiensisproduction of proteases and delta-endotoxins in a low-cost complex medium. Aeration appeared to play an important role in delta-endotoxin production. The correlation between proteolytic activity and aeration does not seem to be reliable. A negative correlation (correlation coefficient =− 0.774) was established between protease activity and delta-endotoxin production. In order to prove this correlation, protease hypo-producing and overproducing mutants were isolated through random mutagenesis of two wild strains, BUPM13 and BUPM5, by using nitrous acid. Interestingly, delta-endotoxin production of BUPM13-1, BUPM13-2 and BUPM13-3 was markedly improved when compared to the wild strainBUPM13, reaching 2.1-fold, 3.69-fold and 8.13-fold, respectively. Maximal protease activity (540-2468 UI) obtained by BUPM5-1 and BUPM5-2 was 2.34-fold and 10.7-fold, respectively, more than that obtained by the wild strain BUPM5 with a drastic decrease of their delta-endotoxin production. Study of delta-endotoxin production by the selected mutants confirmed that insecticidal crystal protein stability in the culture strongly depends on the level of endogenous protease activity. This was also confirmed by bioassays measuring the LC50using larvae ofEphestia kuehniella. Determining protease activity in fermentation culture could be useful in indirectly predicting the potency ofB. thuringiensisstrains with high insecticidal activities. This would allow low-cost selection of overproducing wild isolates or mutants in the screening programmes for the reduction of production cost, which is important from a practical point of view. [ABSTRACT FROM AUTHOR]

The acquisition of the erythromycin resistance by Bacillus thuringiensis kurstaki improved yields of δ-endotoxins in sporulating cells ranging from 134 to 215%. Resistance to erythromycin decreased the final spore count by at least 50%. Consequently, erythromycin resistance is an efficient tool for the improvement of bioinsecticides yields with a high ratio of δ-endotoxins to spores. [ABSTRACT FROM AUTHOR]

Delta-endotoxin production capacity of several Bacillus thuringiensis (Bt) strains exhibiting various larvicidal activities towards either lepidoptera or diptera was investigated in gruel and fish meal media. Diptera-specific strains produced less delta-endotoxins (1246–1998 mg l−1) than lepidoptera-specific ones (3060–3301 mg l−1). Carbon catabolite repression regulated delta-endotoxins synthesis for all strains, but no relationship existed between the specificity of delta-endotoxins and their sensitivity to such repressive regulation. The production of proteolytic activities by the isolate BNS3 and the commercial strain HD1, was reduced in 0.5 g l−1 sodium chloride and 0.1% Tween-80 but not by other strains. Moreover, in the case of the diptera-specific strain BUPM98, there was a need for additional nitrogen sources and to some extent, several amino acids from yeast extract, leading to an increase of 22% in delta-endotoxin production. Sporulation of BUPM98 was never reached in the rich Luria Broth (LB) medium, compared with that of the lepidoptera-specific strain BNS3. In shake flask cultures at 10 g l−1, sodium acetate notably increased (38–79%) delta-endotoxins production by the diptera-specific strains, with a strong decrease in proteolytic activities. Similar delta-endotoxin production and high proteolytic activities were obtained with or without 10 g l−1 sodium acetate with an excess of aeration in a 2-l fermenter. In a less aerated medium, a strong effect of acetate was observed, decreasing production of proteolytic activities and exhibiting high catabolite repression on delta-endotoxin synthesis. The effect of sodium acetate was not directly related to sporulation and protease synthesis but to acetate metabolism. Culture conditions were defined for the screening of Bt strains producing high counts of delta-endotoxins specific to either lepidoptera or diptera. [Copyright &y& Elsevier]