3.1. Selective Recovery of Polyphenolic Fraction from OMWW
Cerasuola-OMWW characterization was performed as described in previous works [
26,
28] and results are summarized in
Table 2.
A valuable use of olive mill wastewaters could be obtained through the valorization of the recovered polyphenolic fraction. Practically, this is a hard task since biophenols are not very stable and can easily get oxidized, hydrolyzed, polymerized, conjugated, and/or complexated in this aqueous environment containing all the reactants (such as metals, enzymes, oxygen, and polysaccharides), required for these kinds of transformations. In a preliminary attempt to identify new, eco-sustainable, and cheaper materials, that are able to selectively adsorb the phenolic fraction (or a fraction of it), three “untraditional” materials were tested: corncob (the maize central core), coffee husk (a waste of the coffee torrefaction process), and volcanic ashes. These materials were chosen both because of their abundant presence in Sicily, and since they constitute wastes (in the case of volcanic ashes, wastes generated by nature itself), and were characterized by relevant disposal costs and/or polluting issues. All tested processes with these materials, regardless of the used conditions, did not give any significant results showing no selective or unselective adsorption property toward the compounds contained in OMWW. In a further attempt, three different commercial polymeric adsorbents (Purosorb™PAD428, Purosorb™PAD900, and Purosorb™PAD550) were tested separately to establish the most suitable to retain completely or partially the phenolic fraction in a selective way.
Different eluents and values of flow or temperature were tested to find a good compromise that would allow the ability to minimize possible oxidation reactions and achieve equilibria between the various phases. The general best conditions were a flow of 0.5 mL/min at 22 °C, and elution with water, to collect the unabsorbed fraction (FR1), followed by a solution of water/ethanol (50/50) in the attempt to selectively desorb the polyphenolic fraction (FR2), and finally with pure ethanol to wash and recycle the adsorbent phase. Analysis of different eluted fractions by HPLC-DAD indicated that only Purosorb™PAD428 and Purosorb™PAD900 were able to completely retain the phenolic compounds. In fact, both aqueous fractions (PAD428-FR1 and PAD900-FR1) presented a slight yellow color and were almost completely deprived of any phenolic component as demonstrated both by chromatograms at 280 nm and by
1H-NMR spectra (data are shown in
Supplementary materials Figures S2–S8); the results reported in
Table 2 show that the eluted aqueous fractions (PAD428-FR1 and PAD900-FR1) had a very low amount of polyphenols (0.40 and 0.38 g/L). Furthermore, the values of COD and BOD were reduced by 40% and 30% respectively, and a slight decrease in the inorganic load was observed too (
Table S1 shown in Supplementary material). On the other hand, high amounts of carbohydrates (not retained by the adsorbent resins) suggest that this fraction could find valuable applications in cosmetic field as described in a recent work [
30].
Conversely, the fractions eluted with the ethanolic mixture (PAD428-FR2 and PAD900-FR2) presented an intense red–brown color and gave again similar results in terms of polyphenols content (up to 4.12 g/L, recovery 80%) as shown by the PAD428-FR2 sample chromatogram reported in
Figure 1, with hydroxytyrosol and tyrosol respectively 0.90–0.85 g/L and 0.10–0.08 g/L as reported in
Table 2. However other biophenols were identified in PAD428-FR2 samples as shown in
Table S2 (see
Supplementary materials).
The maximum volume of Cerasuola-OMWW that can be absorbed by 10 g of both adsorbent resins, before saturation, was 30 mL. Since Purosorb™PAD428 and Purosorb™PAD900 showed very similar adsorbent features, the subsequent adsorption equilibrium tests and scale-up process were carried out employing only the resin Purosorb™PAD428, and biological assays and formulation procedure of the ophthalmic nutraceutical were realized with the corresponding polyphenolic fraction (PAD428-FR2).
3.2. Adsorption Equilibrium and Kinetic Tests
To describe the equilibrium state in the adsorption system, the concept of dynamic equilibrium is commonly used. The liquid/gas molecules striking on the surface of a solid material can be adsorbed or rebounded; the rate of adsorption at the beginning is elevated since the adsorption sites are all available, but it decreases over time as the surface gets covered by adsorbate molecules. Conversely, the desorption rate increases because a greater number of molecules rebound until reaching the equilibrium between the adsorption rate and the desorption rate [
40]. There are several equilibrium isotherm models but the most used and important in the field of adsorption for environmental cleanup are Freundlich and Langmuir isotherms [
41,
42].
After adsorption equilibrium was reached, batch test mixtures were filtered (on filter paper) and collected in test tubes. The resulting solutions for Purosorb™PAD428 resin test are shown in
Figure 2a. The color diminution, that corresponds to the increase in the adsorbent dose (from right to left), was a clear symptom of the removal of the polyphenolic components (that are accounted for the typical reddish OMWW color). The solutions were analyzed, with respect to their content in COD and total polyphenols, and the results (see
Figure 2b) confirmed the visual interpretation.
According to
Figure 2c, a significant increase in total polyphenols removal efficiency was observed when the adsorbent dose to OMWW ratio increased from 1:12 to 1:2. The total polyphenols removal reached 90% at 1:6 ratio (0.17), while the removal rate increase was less pronounced at higher ratios. This result is easily understandable since an increase in the amount of adsorbent material will increase the total surface area and the available adsorption sites, lowering the driving force for intra-particle adsorption at each adsorption site, and resulting in a minor utilization of the adsorption capacity. This leads to the conclusion 1:5 ratio is considered to be a good compromise between removal efficiency and employed quantity of adsorbent.
The isotherm of total polyphenols adsorption onto Purosorb™PAD428 resin is depicted in
Figure 3a, in which the
R2, associated with the Freundlich model fitting, is indicated. It is observed that the curve is concave downward, indicating a favorable isotherm leading to high adsorption capacity, as depicted in the values of Langmuir constants. In the fixed-bed adsorption column, a strongly favorable isotherm would also lead to a short mass transfer zone [
43].
As reported in
Figure 3b, a better representation of results is obtained by the Langmuir isotherm model. This was an expected result since, compared to Freundlich isotherm, this model is more flexible in modeling adsorption from highly concentrated water solutions. This result validates the assumption of monolayer homogenous adsorption of total polyphenols on polymeric resin.
The correlation coefficient R
2 shown in
Table 3 gives privilege for Langmuir isotherm over Freundlich one. The maximum Langmuir capacity Q
0 matches the equilibrium adsorption capacity curve (
Figure 3b).
Langmuir separation factor RL resulted to be equal to 0.084, indicating that the adsorption isotherm of total phenol onto Purosorb™PAD428 resin is favorable (0 < RL < 1). RL values give evidence that the process is reversible, supporting the hypothesis that physical adsorption occurs in this process.
3.4. In Vitro Study and Ophthalmic Nutraceutical Application
Even if natural compounds and extracts are commonly considered free from harmful effects possible safety problems cannot be excluded [
30]. Generally, irritation and cytotoxicity tests are performed to reduce the ocular risk of exposure to dangerous substances. Historically, animal tests such as the in vivo Draize rabbit assay were used to define the level of ocular toxicity by application of a test compound to a live rabbit’s eye and then evaluation of the biological response. Recently, several in vitro alternative techniques have been developed as the result of ethical reconsideration of the animal used for toxicology studies [
44].
For this purpose, we performed an in vitro study by using SIRC cells, a cell line having a mixed epithelial and fibroblastic nature [
45], already used for toxicology studies in ophthalmic field [
46,
47].
Our preliminary interest was to evaluate in vitro the possible cytotoxic effect elicited by the fraction PAD428-FR2.
Figure 6a shows the results of MTT assay, a colorimetric method measuring the reduction of MTT, a yellow-colored tetrazolium salt, to a purple formazan by the mitochondrial dehydrogenase enzyme of living cells [
30,
32]. The MTT assay data obtained on SIRC cells treated with different concentrations of PAD428-FR2 for 24 hours provided evidence to show that the lowest concentration (0.01%) did not influence the cell viability compared to untreated control cells. Conversely, the treatment with higher concentrations (0.02%, 0.05%, and 0.1%) caused a drastic decrease in cell viability in a dose-dependent manner with respect to both untreated control cells and 0.01% treated cells; in particular, these concentrations (0.02%, 0.05%, and 0.1%) were able to induce a dose-dependent necrotic effect as a result of cell membrane disruption (
Figure 6b), in accordance with MTT assay data.
In addition, we evaluated in vitro the potential genotoxic effects of the fraction. Among the different approaches used to study DNA damage, comet assay is a simple and fast method to assess different types of DNA damage at the single-cell level [
48]. In particular, we performed alkaline comet assay that permits to identify DNA double-strand breaks, single-strand breaks, alkali-labile sites, DNA-DNA/DNA-protein cross-linking, and incomplete excision repair sites [
49]. The results, shown in
Figure 6c, provided evidence that the treatment with 0.02% and 0.05% induced DNA damage in a dose-dependent manner.
In order to evaluate the possible mechanism of action, we measured ROS levels by using DCFH-DA, a non-fluorescent molecule that can spread through the cell membrane and, once inside the cell, is enzymatically hydrolyzed by an intracellular esterase to non-fluorescent DCFH; then ROS are able to oxidize DCFH to the fluorescent dichlorofluorescein (DCF), whose fluorescence intensity (FI) is proportional to the level of intracellular ROS [
50].
In our opinion, the observed toxic effects could be related to the ROS overproduction (
Figure 6d), that can determine the accumulation of oxidized intracellular macromolecules influencing the cell viability up until inducing cell death [
51].
Based on these results we decided to continue the study by excluding the highest concentrations (ranging from 0.02% to 0.1%) because of their toxicity for the selected cell line.
It is well known that oxidative stress is involved in the pathogenesis of several eye diseases, such as ocular surface inflammation and dry eye disease [
19,
20]. So we evaluated, for the first time to our knowledge, the antioxidant and anti-inflammatory activities of polyphenolic fraction obtained from OMWW on SIRC cells.
To test the antioxidant activity, SIRC cells were pretreated with PAD428-FR2 0.01% for 24 h and then were stimulated with H
2O
2 (200 µM) for 10 and 30 minutes. The results of the MTT assay (
Figure 7) showed that H
2O
2-treatment reduced cell viability compared to untreated control cell in a time-dependent manner. Moreover, it can be observed that the pretreatment with PAD428-FR2 0.01% determined an increase in cell viability with respect to H
2O
2-treated cells, suggesting a good protective activity of the fraction against the oxidant stimulus. In addition, we performed the alkaline version of the comet assay by using Fpg enzyme that recognizes and cuts the sites corresponding to oxidized guanine bases [
37]. The results, shown in
Figure 8, evidenced that the pretreatment with PAD428-FR2 0.01% was able to protect DNA from oxidative stress induced by H
2O
2 added for 30 min.
As expected, a significant rise of ROS levels was observed in H
2O
2-treated cells with respect to untreated control cells in a time-dependent manner. This increase was counteracted by pre-incubating cells with PAD428-FR2 0.01% (
Figure 9).
Our results are in accordance with Schlupp et al. (2019) who reported the antioxidant activity of a phenol-enriched OMWW extract was able to reduce the formation of free radicals in vitro [
52]. Similar results were obtained by Schaffer et al. (2007) who demonstrated that hydroxytyrosol-rich olive mill wastewater extract was able to protect brain cells from oxidative damage [
53].
Regarding the anti-inflammatory activity, SIRC cells were pretreated with PAD428-FR2 0.01% for 2 h and then were stimulated for 24 h with LPS (1 μg/ml), the major constituent of the outer membrane of Gram-negative bacteria able to elicit inflammation.
As expected, MTT data and immunoblots, shown in
Figure 10 and
Figure 11, revealed that LPS-treatment significantly reduced the percentage of cell viability and increased the expression of TNF-α, a well-known pro-inflammatory mediator involved in ocular inflammation [
38]. The results also revealed that the pretreatment with PAD428-FR2 0.01% determined a marked increase in cell viability and a decrease of TNF-α levels with respect to LPS-treated cells, demonstrating a good protective activity of fraction against the inflammatory stimulus.
These data are in agreement with several in vitro and in vivo studies; for instance, Baci et al. (2019) reported that a polyphenol-rich extract from olive mill wastewater was able to induce a downregulation of pro-inflammatory pathways in prostate cancer cells [
54]. Richard et al. (2011) evidenced that hydroxytyrosol was the major anti-inflammatory compound in aqueous olive extracts able to impair cytokine and chemokine production in murine macrophages stimulated with LPS [
18]. In particular, Fuccelli et al. (2018) observed that hydroxytyrosol reduced the TNF-α secretion in LPS stimulated mouse model [
17].
Based on the previous biological assays, 0.01%
w/
w of lyophilized PAD428-FR2 was used to formulate a novel nutraceutical ophthalmic preparation. Traditional ophthalmic liquid formulations are characterized by limited residence time in the eye due to lacrimal secretion and nasolacrimal drainage resulting in a low drug absorption (only 1–10%) and limited efficacy. The increase of viscosity of the formulation using biocompatible hydrophilic polymers with mucoadhesive properties represents one of the best strategies to prolong the residence time in the eye [
55,
56]. Indeed, several studies have reported that the water-base gels have several advantages over the traditional ophthalmic formulations, either in terms of enhanced therapeutic response or improved ocular bioavailability [
57]. According to these considerations, in this study a combination of different hydrophilic polymers as Carbopol
®980 and Pemulen™RT1-NF was employed to enhance the viscosity and obtain a hydrogel with a 3D polymeric network [
58]. Hydrogel was prepared according to the protocol described in the “Materials and Methods” section, and the final composition is shown in
Table 1.
The ophthalmic formulation was clear without any suspended particles or impurities and showed a pH value equal to 6.7 which is considered physiologically compatible. As reported in the Materials and Methods section, the values regarding pH, appearance, osmolality, and hydroxytyrosol (%) were evaluated to assess the chemical and physical stability in the storage period. The results of stability study, shown in
Table 4, revealed no significant changes with respect to hydroxytyrosol concentration (%), pH, osmolality, and appearance in samples stored at 25 ± 2 °C with 60% ± 5% R.H. for 3 months.
Finally, we evaluated the ocular irritation of hydrogel using SkinEthicTM HCE model, composed of human corneal epithelial cells that forms a corneal epithelial tissue when cultured at the air–liquid interface in a chemically defined medium on a permeable synthetic membrane insert [
39].
The percentage of cell viability evaluated by MTT assay was equal to 95.7 ± 5.3 for tissues treated with hydrogel. According to the viability classification prediction model, since the percentage of viability is more than 60%, the hydrogel can be classified as non-irritant.
3.5. Scaling up and Pilot Plant Development
A mandatory feature for a process aiming to be an applicative and possibly marketable development is economic sustainability. In order to evaluate this parameter and with the aim to test the scalability, reproducibility, and effectiveness of our protocols at a pre-industrial scale too, an automatized pilot plant for polyphenols extraction from OMWW was realized by using the optimized laboratory conditions.
In
Figure 12 is the schematized pilot plant consisting of the following steps: de-oiling and sand removal through a settler and an oil-separator, sand filtration, adsorption process through Purosorb™PAD428 and discharging of the not retained dephenolized fraction (FR1), and finally desorption of the polyphenolic mixture (FR2) stored in a 2000 L accumulation tank by eluting with water\ethanol 50:50. A mixture of ethanol/isopropanol, 85:15, instead of pure ethanol, was used in the desorption phase because it represented the purest composition on the market for semi-industrial use.
The empty bed contact time, with the operating flow, was about 48 min, a sufficient time to reach the maximum adsorption, according to laboratory results.
Preliminary runs in the pilot plant (see
Figure S9 of prototype in Supplementary material) showed that the various fractions have features tending to satisfactorily match the laboratory results but need to be furtherly optimized. This is shown in
Table 5, which compares olive mill wastewaters and fractions FR1/FR2 characteristics, obtained from the treatment in the pilot plant. It is to be noted that the difference in composition between lab and scale-up could partly be explained by the different purity of used eluents.
The FR1 showed a reduced content in polyphenols (more than 50%), and a COD abatement of about 32%. This sugar-enriched fraction was used to develop novel cosmeceutical formulations as described in a previous work [
30]; alternatively, it is possible to imagine for this fraction a final oxidative stage (aerobic microbial digestion) able to furnish clear depolluted water and, as a secondary product, some sludge that could find easy application as compost in agriculture due to its rich organic content. A further reduction of polyphenols content would help the potential subsequent biological sludge treatment, with the addition of urea and ammonium phosphate, to achieve the correct nutritional balance. After evaporation of the solvent, the residues of the FR2 alcoholic extract were analyzed by HPLC (chromatogram not reported): The main components, analogously to the lab-scale process, were tyrosol and hydroxytyrosol, with an average polyphenolic recovery of 22%, and a hydroxytyrosol purity of 40%. The lower polyphenolic recovery value (if compared to laboratory results) needs to be improved and investigations regarding the optimization of the scaling up parameters, especially flow rate and contact time, are actually in progress, but in general these firsts pilot plant operation experiments demonstrated that expected results are not too far from being reached.
In the pilot plant prototype, the total installed power (calculated as the sum of the nominal powers of all power-consuming sections) is about 1 kW, and considering a ten cycle operation, a preliminary economic balance was assessed, as illustrated in
Table 6. Operational only costs were included, while any investment cost was excluded. Noteworthy, by recycling ethanol, that represents one of the major costs in the procedure, a substantial reduction of the total cost could be achieved, but one of the main objectives of subsequent studies should be a better regeneration of the resin and/or the extension of its useful life.