Studies supporting the use of mechanical mixing in large scale beer fermentations

Brewing fermentations have traditionally been undertaken without the use of mechanical agitation, with mixing being provided only by the fluid motion induced by the CO₂ evolved during the batch process. This approach has largely been maintained because of the belief in industry that rotating agitators would damage the yeast. Recent studies have questioned this view. At the bench scale, brewer’s yeast is very robust and withstands intense mechanical agitation under aerobic conditions without observable damage as measured by flow cytometry and other parameters. Much less intense mechanical agitation also decreases batch fermentation time for anaerobic beer production by about 25% compared to mixing by CO₂ evolution alone with a small change in the concentration of the different flavour compounds. These changes probably arise for two reasons. Firstly, the agitation increases the relative velocity and the area of contact between the cells and the wort, thereby enhancing the rate of mass transfer to and from the cells. Secondly, the agitation eliminates spatial variations in both yeast concentration and temperature, thus ensuring that the cells are maintained close to the optimum temperature profile during the whole of the fermentation time. These bench scale studies have recently been supported by results at the commercial scale from mixing by an impeller or by a rotary jet head, giving more consistent production without changes in final flavour. It is suggested that this reluctance of the brewing industry to use (adequate) mechanical agitation is another example where the myth of shear damage has had a detrimental effect on the optimal operation of commercial bioprocessing.     

A mass spectrometry membrane probe and practical problems associated with its application in fermentation processes

A sensor-type, multi-compound monitoring system was constructed to measure several substances dissolved in a culture medium by use of a membrane inlet system coupled with a low-cost quadrupole mass spectrometer. The membrane inlet system was shown to have higher sensitivity with an even faster response than a capillary inlet system. The system was able to monitor on-line gaseous (H₂, CO₂ and O₂) and volatile (ethanol, butanol, acetone, acetic acid and ethyl acetate) compounds at concentrations in a range suitable for fermentation process monitoring applications. The effects of temperature, agitation speed and pressure on measurements using the membrane inlet system were investigated. For volatile compound measurements, temperature and pressure had an effect on the response but the agitation speed did not. A high concentration of compounds caused measurement saturation due to the space charge effect, but this could be overcome by reducing the surface area of the membrane. The system was applied to the monitoring of ethanol in a yeast cultivation. Measurements were affected by CO₂ produced during the fermentation, but this could be compensated for by means of a linear empirical equation. The system demonstrated high potentiality for application to the on-line monitoring of multiple compounds in fermentation processes.     

Cultivation of baker's yeast by a fermenter with a basket-shaped unit for agitation

A simple and new basket-shaped unit for agitation made of stainless wire was developed. A fermenter equipped with this unit attained higher k_La, than 3500 h^–1 under the condition with an aeration rate 2vvm and a rotation speed of the unit 1100rpm. In the cultivation of baker's yeast, the cell concentration reached about 110g per liter on dry weight basis in 17.5h.     

Effects of CO<Subscript>2</Subscript> on the formation of flavour volatiles during fermentation with immobilised brewer’s yeast

Immobilised-cell fermentors offer great benefits compared to traditional free-cell systems. However, a major problem is unbalanced flavour production when these fermentors are used for the production of alcoholic beverages. One of the keys to obtaining better control over flavour formation may be the concentration of dissolved CO₂, which has inhibitory effects on yeast growth and metabolism. This article demonstrates that the presence of immobilisation matrices facilitates the removal of CO₂ from the liquid medium, which results in a low level of dissolved CO₂ during fermentation. Moreover, the formation of volatile higher alcohols and esters was greatly enhanced in the immobilised-cell system when compared to the free cell system. By sparging a CO₂ flow (45 ml/min) into the immobilised-cell system, cell growth was reduced by 10–30% during the active fermentation stage, while the fermentation rate was unaffected. The uptake of branched-chain amino acids was reduced by 8–22%, and the formation of higher alcohols and esters was reduced on average by 15% and 18%, respectively. The results of this study suggest that mismatched flavour profiles with immobilised-cell systems can be adjusted by controlling the level of dissolved CO₂ during fermentation with immobilised yeast.     

Fed-batch fermentation of indole-3-acetic acid production in stirred tank fermenter by red yeast <Emphasis Type="Italic">Rhodosporidium paludigenum</Emphasis>

Indole-3-acetic acid (IAA) is a significant secondary metabolite that is the most important auxin of plant hormones. Production of IAA is considered to be a key trait to support plant growth. The improvement of IAA production by a basidiomycetous red yeast Rhodosporidium paludigenum DMKU-RP301 was investigated. Batch and fed-batch fermentation of R. paludigenum DMKU-RP301 were conducted in a 2 L stirred tank fermenter. Using batch fermentation, it was found that when cultivated at an agitation speed of 200 rpm and a 3 L/min aeration rate, this yeast produced IAA at its maximum level of 1,627.1 mg/L (9.7 mg/L/h). In fed-batch fermentation, a higher level of maximum IAA production than that found in batch fermentation was observed, i.e. 2,743.9 mg/L (25.4 mg/L/h). It is therefore suggested that fed-batch fermentation improves the efficiency of IAA production in terms of product concentration and IAA productivity. Moreover, yeast carotenoid production was also investigated using R. paludigenum DMKU-RP301, and found a maximum carotenoid production of 3.05 mg/L.     

Dissolved oxygen as principal parameter for conidia production of biocontrol fungi Trichoderma viride in non-Newtonian wastewater

Dissolved oxygen (DO) concentration was selected as a principal parameter for translating results of shake flask fermentation of Trichoderma viride (biocontrol fungi) to a fermenter scale. All fermentations were carried out in a 7.5 l automated fermenter with a working volume of 4 l. Fermentation performance parameters such as volumetric oxygen transfer coefficient (k _L a), oxygen uptake rate (OUR), rheology, conidia concentration, glucose consumption, soluble chemical oxygen demand, entomotoxicity and inhibition index were measured. The conidia concentration, entomotoxicity and inhibition index were either stable or improved at lower DO concentration (30%). Variation of OUR aided in assessing the oxygen supply capacity of the fermenter and biomass growth. Meanwhile, rheological profiles demonstrated the variability of wastewater during fermentation due to mycelial growth and conidiation. In order to estimate power consumption, the agitation and the aeration requirements were quantified in terms of area under the curves, agitation vs. time (rpm h), and aeration vs. time (lpm h). This simple and novel strategy of fermenter operation proved to be highly successful which can be adopted to other biocontrol fungi.     

An industrial level system with nonisothermal simultaneous solid state saccharification,fermentation and separation for ethanol production

To alleviate the problems of low substrate loading, nonisothermal, end-product inhibition of ethanol during the simultaneous saccharification and fermentation, a nonisothermal simultaneous solid state saccharification, fermentation, and separation (NSSSFS) process was investigated; one novel pilot scale nonisothermal simultaneous solid state enzymatic saccharification and fermentation coupled with CO₂ gas stripping loop system was invented and tested. The optimal pretreatment condition of steam-explosion was 1.5 MPa for 5 min in industrial level. In the NSSSFS, enzymatic saccharification and fermentation proceeded at around 50 °C and 37 °C, respectively, and were coupled together by the hydrolyzate loop; glucose from enzymatic saccharification was timely consumed by yeast, and the formed ethanol was separated online by CO₂ gas stripping coupled with adsorption of activated carbon; the solids substrate loading reached 25%; ethanol yields from 18.96% to 30.29% were obtained in fermentation depending on the materials tested. Based on the pilot level of 300 L fermenter, a novel industrial-level of 110 m³ solid state enzymatic saccharification, fermentation and ethanol separation plant had been successfully established and operated. The NSSSFS was a novel and feasible engineering solution to the inherent problems of simultaneous saccharification and fermentation, which would be used in large scale and in industrial production of ethanol.     

Alginate production by <Emphasis Type="Italic">Pseudomonas mendocina</Emphasis> in a stirred draft fermenter

In this study alginate production by Pseudomonas mendocina in a laboratory-scale fermenter was investigated. In the experiments the effect of temperature (25–31°C) and agitation (500–620 rev min⁻¹) at a constant air flow of 10 v/v/h were evaluated in relation to the rate of glucose bioconversion to alginate using response surface methodology (RSM). The fermenter configuration was also adapted to a system with a screw mixer and draft tube, due to the change in rheological characteristics of the fermentation broth. The adjusted model indicates a temperature of 29.1°C and agitation of 553 rev min⁻¹ for optimum alginate synthesis. In this fermentation system a Y _p/s of 44.8% was achieved. The alginate synthesized by P. mendocina showed a partially acetylated pattern as previously reported for alginates obtained from other Pseudomonas spp and Azotobacter vinelandii.     

The inhibitory effect of ethanol on ethanol production by Zymomonas mobilis

Summary In an effort to establish the reasons for the limitations in the final ethanol concentration of Zymomonas mobilis fermentation, the effects of CO₂ and ethanol on the fermentation were investigated using continuous and fed-batch cultivation systems. The nucleation and stripping out of CO₂ from the fermenter using diatomaceous earth or nitrogen gas or both exhibited a profound effect on the glucose uptake rate during the early stages of fed-batch fermentation, but did not improve final ethanol yields. The addition of ethanol together with above mentioned experiments confirmed conclusively that ethanol inhibition is responsible for the final ethanol concentration obtainable during Zymomonas mobilis fermentation. The final concentration lies between 90 and 110 gl⁻¹ or approximately 12–15% (v/v) ethanol.     

The effect of carbon dioxide,aeration rate and sodium chloride on the secretion of proteins from growing bakers' yeast (Saccharomyces cerevisiae)

Since yeast may be an important microorganism for industrial use when its genes are modified by recombinant DNA techniques to overproduce certain proteins, (particularly those which are glycosylated), it is desirable to study how environmental variables affect its protein secretion ability. It is also of interest to understand how proteins such as proteases, lipases and amylases are excreted in solid matrices to develop a basis for learning more about solid fermentations. With these two applications in mind, the total protein excreted by both aerated and non-aerated Saccharomyces cerevisiae growing in a liquid batch culture (with varying levels of CO₂ and NaCl) was tracked. Using a modified Bradford method (Coomassie Blue dye-binding assay) for the concentration of total proteins in the extracellular fermentation broth, it has been determined that by 24 h of the run, excreted proteins rose to levels of about 10% of the total cell protein (500 μg ml^?1 protein from about 10 g of yeast, containing about 5 g total protein). No cell lysis was observed during the 24 h run. The highest protein levels at the top of the fermentor seemed to be those achieved in response to CO₂ alone. Additions of NaCl did not seem to enhance the secreted protein level. Large inconsistencies in replicating anaerobic runs for protein concentration appeared to be explained by noting that rising CO₂ bubbles may cause ‘foam fractionation’ of the proteins in the broth.     

Studies on the energy metabolism during anaerobic fermentation of glucose by baker's yeast

Summary As a result of the intimate association of ADP phosphorylation with alcoholic fermentation, resulting in the synthesis of 2 mole ATP per mole glucose fermented, it may be calculated that a minimum of 672 µcal heat development may be expected for every mm³ CO₂ developed during alcoholic fermentation. When all ATP produced would be fully de-phosphorylated to ADP + Pi (e.g. by ATP-ase activity) a maximum heat development of 1200 µcal per mm³ CO₂ could be expected.Using the LKB-Flow-Microcalorimeter for measurement of heat development and at the same time the Warburg technique for measuring CO₂ development during anaerobic glucose fermentation of a baker's yeast suspension, the heat development per mm³ CO₂ produced was calculated over a fermentation period of 90 min.Maintenance of strict anaerobic conditions in the Flow-Microcalorimeter vessel was complicated by diffusion of traces of oxygenvia the Teflon transport lines, resulting in excessive heat development values, not representative for the alcoholic fermentation. This problem could be circumvented by removal of traces of oxygen by means of addition of the enzyme glucose-oxidase.Poisoning the respiratory enzyme system of the yeast by addition of KCN or azide, or using respiratory-deficient mutants of the yeast also resulted in heat development values, inherent with alcoholic fermentation.The values obtained were very close to the minimum of 672 µcal per mm³ CO₂, at least during the initial phases of fermentation, indicating that ADP regeneration from ATP, essential for maintaining the high fermentation rate, is not primarily the result of ATP-ase activity, but must be due to participation of ATP in energy-requiring synthetic reactions.     

Optimization of exopolysaccharide production from Armillaria mellea in submerged cultures

Aims: To study the optimization of submerged culture conditions for exopolysaccharide (EPS) production by Armillaria mellea in shake‐flask cultures and also to evaluate the performance of an optimized culture medium in a 5‐l stirred tank fermenter. Methods and Results: Shake flask cultures for EPS optimal nutritional production contained having the following composition (in g l^?1): glucose 40, yeast extract 3, KH₂PO₄ 4 and MgSO₄ 2 at an optimal temperature of 22°C and an initial of pH 4·0. The optimal culture medium was then cultivated in a 5‐l stirred tank fermenter at 1 vvm (volume of aeration per volume of bioreactor per min) aeration rate, 150 rev min^?1 agitation speed, controlled pH 4·0 and 22°C. In the optimal culture medium, the maximum EPS production in a 5‐l stirred tank fermenter was 588 mg l^?1, c. twice as great as that in the basal medium. The maximum productivity for EPS (Q_p) and product yield (Y_P/S) were 42·02 mg l^?1 d^?1 and 26·89 mg g^?1, respectively. Conclusions: The optimal culture conditions we proposed in this study enhanced the EPS production of A. mellea from submerged cultures. Significance and Impact of the Study: The optimal culturing conditions we have found will be a suitable starting point for a scale‐up of the fermentation process, helping to develop the production of related medicines and health foods from A. mellea.     

Fermentation of Detoxified Acid-Hydrolyzed Pyrolytic Anhydrosugars into Bioethanol with <Emphasis Type="Italic">Saccharomyces cerevisiae</Emphasis> 2.399

Pyrolysate obtained from the pyrolysis of waste cotton is a source of fermentable sugars that could be fermented into bioethanol fuel and other chemicals via microbial fermentation. However, pyrolysate is a complex mixture of fermentable and non-fermentable substrates causing inhibition of the microbial growth. The aim of this study was to detoxify the hydrolysate and then ferment it into bio-ethanol fuel in shake flasks and fermenter applying yeast strain Saccharomyces cerevisiae 2.399. Pyrolysate was hydrolyzed to glucose with 0.2 M sulfuric acid, neutralized with Ba(OH)₂ followed by treatment with ethyl acetate and activated carbon to remove fermentation inhibitors. The effect of various fermentation parameters such as inoculum concentration, pH and hydrolysate glucose was evaluated in shake flasks for optimum ethanol fermentation. With respect to inoculum concentration, 20% v/v inoculum i.e. 8.0 × 10⁸–1.2 × 10⁹ cells/mL was the optimum level for producing 8.62 ± 0.33 g/L ethanol at 9 h of fermentation with a maximum yield of 0.46 g ethanol/g glucose. The optimum pH for hydrolysate glucose fermentation was found to be 6.0 that produced 8.57 ± 0.66 g/L ethanol. Maximum ethanol concentration, 14.78 g/L was obtained for 4% hydrolysate glucose concentration after 16 h of fermentation. Scale-up studies in stirred fermenter produced much higher productivity (1.32 g/L/h^–1) compared to shake flask fermentation (0.92 g/L/h^–1). The yield of ethanol reached a maximum of 91% and 89% of the theoretical yield of ethanol in shake flasks and fermenter, respectively. The complex of integrated models of development was applied, that has been successfully tested previously for the mathematical analysis of the fermentation processes.     

The role of aeration and agitation in the production of glucose oxidase in submerged culture. II

The main purpose of the work reported here was to establish the effectiveness of aeration and agitation, and to determine the best conditions of aeration for the growth and production of glucose oxidase of Aspergillus niger, on a semi-industrial scale. Concentration of dissolved O₂, O₂ consumption and CO₂ production were measured. It was found that the rate of growth and the activity of glucose oxidase per gram mycelium increased with the increase of speed of agitation. The concentration of dissolved oxygen of the fermentation broth, as well as the rate of respiration (O₂ consumption and CO₂ production) increased in direct proportion to the increase of speed of agitation, while assimilation of sugars was accelerated. The values of the respiratory ratio showed a fluctuation according to the presence or absence of sugar in the medium.     

Glycerol Production by Fermenting Yeast Cells Is Essential for Optimal Bread Dough Fermentation

Glycerol is the main compatible solute in yeast Saccharomyces cerevisiae. When faced with osmotic stress, for example during semi-solid state bread dough fermentation, yeast cells produce and accumulate glycerol in order to prevent dehydration by balancing the intracellular osmolarity with that of the environment. However, increased glycerol production also results in decreased CO₂ production, which may reduce dough leavening. We investigated the effect of yeast glycerol production level on bread dough fermentation capacity of a commercial bakery strain and a laboratory strain. We find that Δgpd1 mutants that show decreased glycerol production show impaired dough fermentation. In contrast, overexpression of GPD1 in the laboratory strain results in increased fermentation rates in high-sugar dough and improved gas retention in the fermenting bread dough. Together, our results reveal the crucial role of glycerol production level by fermenting yeast cells in dough fermentation efficiency as well as gas retention in dough, thereby opening up new routes for the selection of improved commercial bakery yeasts.     

Carbon dioxide inhibition of yeast growth in biomass production

Saccharomyces cerevisiae was grown under aerobic and substrate-limiting conditions for efficient biomass production. Under these conditions, where the sugar substrate was fed incrementally, the growth pattern of the yeast cells was found to be uniform, as indicated by a constant respiratory quotient during the entire growing period. The effect of carbon dioxide was investigated by replacing portions of the nitrogen in the air stream with carbon dioxide, while maintaining the oxygen content at the normal 20% level, so that identical oxygen transfer rate and atmospheric pressure were maintained for all experiments with different partial pressures of carbon dioxide. Inhibition of yeast growth was negligible below 20% CO₂ in the aeration mixture. Slight inhibition was noted at the 40% CO₂ level and significant inhibition was noted above the 50% CO₂, level, corresponding to 1.6 × 10^?2M of dissolved CO₂ in the fermentor broth. High carbon dioxide content in the gas phase also inhibited the fermentation activity of baker's yeast.     

Continuous ethanol production in the gas-lift tower fermenter

Summary A highly flocculent strain of Saccharomyces uvarum was used to convert glucose to ethanol and CO₂ in a single stage, continuous, gas-lift tower fermenter. Satisfactory operation was maintained in prolonged runs with yeast concentrations in excess of 100 g/L (d.w.) and hydraulic retention times less than 0.4 h. Maximum ethanol concentration and productivity were 88 g/L and 44.5 g/Lh respectively. Conversion efficiency was between 80 and 95% of theoretical.     

Spektralphotometrische in-situ-Messungen der diffusen Reflexion bei der mikrobiellen Kohlenwasserstoffwandlung

The spectrophotometrical measurement of the diffuse reflectance in fermentation media has been proved useful for the analytical control of the microbial biosynthesis and transformation. A laboratory steril fermenter was fitted at an UV/VIS-spectrophotometer equipped with a diffuse reflectance attachment. The apparent absorbance ΔE₈₍₃₂₈₎ of aromatic hydrocarbons and the reciprocal scattering E₈₍₆₅₀₎ have been compared with parameters of the discontinuous fermentation of the yeast Lodderomyces elongisporus and the bacteria strain EB 10_c on petroleum hydrocarbons as a substrat.     

Influence of the mycotoxins aflatoxin B1, rubratoxin B,patulin and diacetoxyscirpenol on the fermentation activity of baker's yeast

The fermentation activity of baker's yeast (measured by the amount of produced CO₂) is inhibited by 100µg/ml and 10µg/ml aflatoxin B₁, and by 100µg/ml and 10µg/ml diacetoxyscirpenol. Lower concentrations of these mycotoxins as well as of rubratoxin B enhance the fermentation. Only 0.001µg/ml aflatoxin B₁, 0.00001µg/ml diacetoxyscirpenol and 0.01µg/ml rubratoxin B are without effect or slightly inhibitory. Patulin in all concentrations tested does not influence the CO₂ production significantly. Cytochemical studies show that the enzyme alcohol dehydrogenase is inhibited by 100µg/ml and enhanced by 1µg/ml and 0.1µg/ml aflatoxin B₁. It is suggested that the influence of at least aflatoxin B₁ on the fermentation activity of the yeast cells is due to an interaction with alcohol dehydrogenase. It is possible that the activity of other enzymes of yeast is also influenced by mycotoxins.     

Application of carbon balance to submerged citric acid production by Aspergillus niger

Summary In an air-lift fermenter, the following production was obtained from 125 g sucrose in mineral medium at pH 2.5 : 15.76 g mycelium dry wt, 107.2 g citric acid anhydrous and 0.594 mol CO₂ within 138 h (run I) and 13.72 g mycelium dry wt, 114.28 g citric acid and 0.516 mol CO₂ within 144 h (run II). Initially, the carbon content of consumed sugar and products did not balance. At the end of fermentation, the carbon content of the products was 0.9%–5.5% higher than that of the consumed sugar. For the purpose of the calculations the carbon content in mycelium was accepted as 0.462.The work was a part of Project No 04.11 CPBP, topic No 2.24