Butanol from whey ultrafiltrate: batch experiments with Clostridium beyerinckii LMD 27.6

Summary For batch fermentations by Clostridium beyerinckii LMD 27.7 (formerly known as Clostridium butylicum) whey ultrafiltrate, glucose, lactose, and galactose were used as substrates. The aims of the experiments were to find the conditions for butanol production from whey ultrafiltrate and to compare the results with those of other substrates. The conditions necessary for butanol production were established. The mean solvent productivity found on whey ultrafiltrate fermentation was two to three times lower than that found on glucose; the overall solvent yields were comparable. Butanol production from galactose and mixtures of glucose and galactose was also possible.     

Batch fermentation of whey ultrafiltrate by Lactobacillus helveticus for lactic acid production

Summary Cheese whey ultrafiltrate (WU) was used as the carbon source for the production of lactic acid by batch fermentation with Lactobacillus helveticus strain milano. The fermentation was conducted in a 400 ml fermentor at an agitation rate of 200 rpm and under conditions of controlled temperature (42° C) and pH. In the whey ultrafiltrate-corn steep liquor (WU-CSL) medium, the optimal pH for fermentation was 5.9. Inoculum propagated in skim milk (SM) medium or in lactose synthetic (LS) medium resulted in the best performance in fermentation (in terms of growth, lactic acid production, lactic acid yield and maximum productivity of lactic acid), as compared to that propagated in glucose synthetic (GS) medium. The yeast extract ultrafiltrate (YEU) used as the nitrogen/growth factor source in the WU medium at 1.5% (w/v) gave the highest maximum productivity of lactic acid of 2.70 g/l-h, as compared to the CSL and the tryptone ultrafiltrate (TU). L. helveticus is more advantageous than Streptococcus thermophilus and Lactobacillus delbrueckii for the production of lactic acid from WU. The L. helveticus process will provide an alternative solution to the phage contamination in dairy industries using Lactobacillus bulgaricus.     

Semicontinuous lactic fermentation of whey by Lactobacillus bulgaricus. II. Mathematical model

Summary A mathematical model is proposed to explain the empirical Monod-like equation that correlates the lactic acid productivity and the volume fraction of inoculum in semicontinuous fermentation of whey byLactobacillus bulgaricus.     

Patterns of energy metabolism and growth kinetics of Kluyveromyces marxianus in whey chemostat culture

The influence of physiological parameters such as carbon substrate flux and O₂ uptake rates on energy metabolism are reported with reference to biomass productivity in whey chemostat culture. The combined results show that oxidoreductive energy metabolism may be attained independently of the yeast reaching its maximum respiratory capacity. A novel metabolic interpretation is presented proposing that a relative imbalance between glycolysis and subsequent oxidative steps alone is sufficient to account for the observed results. By means of a mathematical model the results could be reproduced under all experimental conditions. The new interpretation provides an insight into the manner in which energy mettbolism is regulated and influences growth-related process Kluyveromyces marxianus, as well as other yeasts with similar physiological characteristics. Correspondence to: J. I. Castrillo     

Dialysis Continuous Process for Ammonium-Lactate Fermentation: Improved Mathematical Model and Use of Deproteinized Whey

Separate terms for substrate limitation and product inhibition were incorporated into an equation describing the rate of cell growth for the steady-state fermentation of lactose to lactic acid with neutralization to a constant pH by ammonia. The equation was incorporated into a generalized mathematical model of a dialysis continuous process for the fermentation, developed previously, in which the substrate is fed into the fermentor and the fermentor contents are dialyzed through a membrane against water. The improved model was used to simulate the fermentation on a digital computer, and the results agreed with previous experimental tests using whole whey as the substrate. Further simulations were then made to guide experimental tests using deproteinized whey as the substrate. Dried cheese-whey ultrafiltrate was rehydrated with tap water to contain 242 mg of lactose per ml, supplemented with 8 mg of yeast extract per ml, charged into a 5-liter fermentor without sterilization, adjusted in pH (5.5) and temperature (44°C), and inoculated with an adapted culture of Lactobacillus bulgaricus. The fermentor and dialysate circuits were connected, and a series of steady-state conditions was managed nonaseptically for 71 days. The fermentation of deproteinized whey relative to whole whey, with both highly concentrated, resulted in similar extents of product accumulation but at a lesser rate.     

Continuous butanol production from whey permeate with immobilized Clostridium beyerinckii LMD 27.6

Summary The aim of this study was to find the conditions necessary for the continuous butanol production from whey permeate with Clostridium beyerinckii LMD 27.6, immobilized in calcium alginate beads. The influence of three parameters on the butanol production was investigated: the fermentation temperature, the dilution rate (during start-up and at steady state) and the concentration of calcium ions in the fermentation broth. It was found that both a fermentation temperature of 30° C and a dilution rate of 0.1 h^-1 or less during the start-up phase are required to achieve continuous butanol production from whey permeate. Butanol can be produced continuously from whey permeate in reactor productivities sixteen times higher than those found in batch cultures with free C. beyerinckii cells on whey media.     

In situ separation of lactic acid from fermentation broth using ion exchange resins

Lactic acid fermentation is an end product inhibited reaction. In situ separation of lactic acid from fermentation broth using ion exchange resins was investigated and compared with conventional fermentation system. Amberlite resin (IRA-400, Cl⁻) was used to separate lactic acid from fermentation broth and pH was controlled online with an automatic pH controller. The effect of process variables on lactic acid production by Lactobacillus casei in whey permeate was studied. The maximum productivity was obtained at pH = 6.1, T = 37 °C and impeller speed = 200 rpm. The maximum concentration of lactic acid at optimum condition was found to be 37.4 g/L after 38 h of fermentation using in situ separation system. The productivity of in situ separation system was five times increased in comparison with conventional system.     

Kinetics of ethanol production by baker's yeast in an integrated process of fermentation and microfiltration

The productivity of a fermentation is proportional to the biomass concentration. The productivity can therefore be increased by retention of the cells in the fermentor. In this study microfiltration was used for cell retention in a fermentation of glucose to ethanol by baker's yeast. Compared to a system without cell retention the productivity could be increased 12-fold to 55 kg/m³ h at a biomass concentration of 135 kg/m³. Maximal ethanol concentrations of 76 kg/m³ were obtained at conditions of growth. At zero growth conditions in the integrated system the ethanol concentration could be increased to about 115 kg/m³, and could be produced for at least 10 hours. The fermentation results in the integrated system could be described reasonably well with a mathematical model based on a different linear inhibition kinetics for growth and substrate consumption.     

Optimization of S-adenosyl-L-methionine production by Kluyveromyces lactis on whey in batch culture using a mathematical model

Growth, lactose utilization and S-adenosyl-l-methionine (AdoMet) production by Kluyveromyces lactis AM-65 on whey in batch fermentation were investigated and an unstructured model of the process has been derived. The optimal set of parameters was estimated by fitting the model to experimental results. After incubation for 20 h the optimal fermentation conditions (28.5 °C, pH 5.3, agitation at 270 rpm) resulted in AdoMet production at 1.55 g l^–1.     

Scaling-up of a batch whey fermentation by Kluyveromyces fragilis

Summary A whey fermentation by Kluyveromyces fragilis was scaled-up to a 1000-dm³ stirred fermentor, by varying the stirrer speed, the air-flow rate and the initial concentration of lactose. Its evolution was simulated by applying the same unstructured model (consisting of a microbial specific growth rate of pseudo-first order with respect to the COD concentration and constant biomass yield per unit COD removed) set up in previous experiments using 8- to 80-dm³ fermentors. Despite the great scale-up ratios, very different operating conditions, and geometric dissimilarity, a series of empirical regressions previously developed allowed approximate, but acceptable prediction of the stoichiometric and kinetic coefficients of the above mathematical model, thus confirming the capability of this model to provide a reliable basis for further scale-up of this fermentation process to a production scale.     

Continuous lactic acid fermentation of whey to produce a ruminant feed supplement high in crude protein

A mathematical model was developed to simulate, on a digital computer, the continuous fermentation of whey lactose to lactic acid with neutralization by ammonia. The simulation predicted the retention times for experimental test and the use of two stages for greatest efficiency. In the experimental tests, Lactobacillus bulgaricus was inoculated into whey in a 14-liter continuous fermentor at 44°C and with automatic pH control. A series of steady-state conditions was managed nonaseptically for 42 days without evident contamination and with an actual increase in the efficiency of conversion. Lactic acid was produced predominately' throughout the period, with less than 0.2% of other compounds. The product contained approximately 8 times as much crude protein (N × 6.25) as the original whey. In a single-stage fermentation at pH 5.5, a retention time of 15 hr resulted in a residual lactose concentration of 0.7%; and little improvement was realized by increasing the retention time. Increasing the pH to 5.8 resulted in a significant improvement, but further increasing the pH to 6.0 resulted in only a small additional gain. By the employment of two fermentors in series at pH 5.5 with a total retention time of 31 hr, the residual lactose was reduced to less than 0.1%. Lactic acid was produced as a function mainly of maintenance rather than growth metabolism.     

A phenomenological model to represent the kinetics of growth by <Emphasis Type="Italic">Corynebacterium glutamicum</Emphasis> for lysine production

Corynebacterium glutamicum is commonly used for lysine production. In the last decade, several metabolic engineering approaches have been successfully applied to C. glutamicum. However, only few studies have been focused on the kinetics of growth and lysine production. Here, we present a phenomenological model that captures the growth and lysine production during different phases of fermentation at various initial dextrose concentrations. The model invokes control coefficients to capture the dynamics of lysine and trehalose synthesis. The analysis indicated that maximum lysine productivity can be obtained using 72 g/L of initial dextrose concentration in the media, while growth was optimum at 27 g/L of dextrose concentration. The predictive capability was demonstrated through a two-stage fermentation strategy to enhance the productivity of lysine by 1.5 times of the maximum obtained in the batch fermentation. Two-stage fermentation indicated that the kinetic model could be further extended to predict the optimal feeding strategy for fed-batch fermentation.     

β-Mannanase production and kinetic modeling from carob extract by using recombinant Aspergillus sojae

The main objectives of this study were to optimize β-mannanase fermentation conditions by using Response Surface Methodology (RSM) and to model kinetically using the kinetic models. Based on the results, the optimum fermentation conditions were found to be initial sugar concentration of 10°Bx, whey concentration of 0.75% [w/v], and inoculum size of 8% (v/v). Under optimized conditions, β-mannanase activity (P), sugar consumed (ΔS), maximum β-mannanase production rate (Q_P), and sugar utilization yield (SUY) were 687.89 U/mL, 47.38 g/L, 118.54 U mL^–1 day^–1, and 69.73%, respectively. Kinetic models were employed to describe the optimum β-mannanase fermentation process. The kinetic analysis of β-mannanase fermentation showed that β-mannanase fermentation is growth associated because the α value (U/mgX) is approximately 330-fold higher than the β value (U/mgX·hr). Nevertheless, maintenance value (Z) was lower than γ value, thus showing that Aspergillus niger mainly utilizes the sugars for β-mannanase production and fungal growth. Consequently, carob extract and whey powder could be used to be cost-effective carbon and organic nitrogen sources, respectively. It was clearly indicated that the suggested kinetic models can successfully describe the fungal growth, β-mannanase production, and substrate consumption.     

Semicontinuous lactic fermentation of whey byLactobacillus bulgaricus I. Experimental results

Summary A Monod-like equation correlates the lactic acid productivity and the volume fraction of inoculum in semicontinuous fermentation of whey byLactobacillus bulgaricus. The volume of the inoculum varied from 10% to 80% of the reactor working volume.Nomenclature N number of fermentation cycles after the first fermentation - P lactic acid productivity - S_w average total sugars concentration of the whey as lactose (the standard deviation is indicated) - T average fermentation time (the standard deviation is indicated) - V_a average total consumption of NH₄OH solution (the standard deviation is indicated) - V_i volume of recently fermented medium used as inoculum of the next fermentation cycle - V_w volume of whey added to the reactor at the beginning of each fer mentation cycle - volume fraction of inoculum=V_i/(V_i+V_w)     

Alcohol production by selected yeast strains in lactase-hydrolyzed acid whey

Ethanol production by Kluyveromyces fragilis and Saccharomyces cerevisiae was studied using cottage cheese whey in which 80 to 90% of the lactose present had been prehydrolyzed to glucose and galactose. Complete fermentation of the sugar by K. fragilis required 120 hr at 30°C in lactase-hydrolyzed whey compared to 72 hr in nonhydrolyzed whey. This effect was due to a diauxic fermentation pattern in lactase-hydrolyzed whey with glucose being fermented before galactose. Ethanol yields of about 2% were obtained in both types of whey when K. fragilis was the organism used for fermentation. Saccharomyces cerevisiae produced alcohol from glucose more rapidly than K. fragilis, but galactose was fermented only when S. cerevisiae was pregrown on galactose. Slightly lower alcohol yields were obtained with S. cerevisiae, owing to the presence of some lactose in the whey which was not fermented by this organism. Although prehydrolysis of lactose in whey and whey fractions is advantageous in that microbial species unable to ferment lactose may be utilized, diauxie and galactose utilization problems must be considered.     

Dialysis Continuous Process for Ammonium-Lactate Fermentation of Whey: Experimental Tests

Laboratory experiments were conducted to validate theoretical predictions describing a dialysis continuous process for the fermentation of whey lactose to ammonium lactate, in which the fermentor contents are poised at a constant pH by adding ammonia solution and dialyzed through a membrane against water. Dried sweet-cheese whey was rehydrated to contain 230 mg of lactose per ml, supplemented with 8 mg of yeast extract per ml, charged into a 5-liter fermentor without sterilization, adjusted in pH (5.3) and temperature (44°C), and inoculated with Lactobacillus bulgaricus. The fermentor and dialysate circuits were connected, and steady-state conditions were established. A series of such conditions was managed nonaseptically for 94 days to study the process and to demonstrate efficiency and productivity. As time progressed, the fermentation remained homofermentative and increased in conversion efficiency, although membrane fouling necessitated dialyzer cleaning about every 4 weeks. With a retention time of 19 h, 97% of the substrate was converted into products. Relative to nondialysis continuous or batch processes for the fermentation, the dialysis continuous process enabled the use of more concentrated substrate, was more efficient in the rate of substrate conversion, and additionally produced a second effluent of less concentrated but purer ammonium lactate.     

Production of bioethanol from organic whey using <Emphasis Type="Italic">Kluyveromyces marxianus</Emphasis>

Ethanol production by K. marxianus in whey from organic cheese production was examined in batch and continuous mode. The results showed that no pasteurization or freezing of the whey was necessary and that K. marxianus was able to compete with the lactic acid bacteria added during cheese production. The results also showed that, even though some lactic acid fermentation had taken place prior to ethanol fermentation, K. marxianus was able to take over and produce ethanol from the remaining lactose, since a significant amount of lactic acid was not produced (1–2 g/l). Batch fermentations showed high ethanol yield (~0.50 g ethanol/g lactose) at both 30°C and 40°C using low pH (4.5) or no pH control. Continuous fermentation of nonsterilized whey was performed using Ca-alginate-immobilized K. marxianus. High ethanol productivity (2.5–4.5 g/l/h) was achieved at dilution rate of 0.2/h, and it was concluded that K. marxianus is very suitable for industrial ethanol production from whey.     

Production of poly(3-hydroxybutyrate) from whey by cell recycle fed-batch culture of recombinant Escherichia coli

A new fermentation strategy using cell recycle membrane system was developed for the efficient production of poly(3-hydroxybutyrate) (PHB) from whey by recombinant Escherichia coli strain CGSC 4401 harboring the Alcaligenes latus polyhydroxyalkanoate (PHA) biosynthesis genes. By cell recycle, fed-batch cultivation employing an external membrane module, the working volume of fermentation could be constantly maintained at 2.3 l. The final cell concentration, PHB concentration and PHB content of 194 g l^–1, 168 g l^–1 and 87%, respectively, were obtained in 36.5 h by the pH-stat cell recycle fed-batch culture using whey solution concentrated to contain 280 g lactose l^–1 as a feeding solution, resulting in a high productivity of 4.6 g PHB l^–1 h^–1.     

Batch and continuous cultivation of Anaerobiospirillum succiniciproducens for the production of succinic acid from whey

Batch and continuous cultivation of Anaerobiospirillum succiniciproducens were systematically studied for the production of succinic acid from whey. Addition of 2.5 g l⁻¹ yeast extract and 2.5 g l⁻¹ polypeptone per 10 g l⁻¹ whey was most effective for succinic acid production from both treated and nontreated whey. When 20 g l⁻¹ nontreated whey and 7 g l⁻¹ glucose were used as cosubstrates, the yield and productivity of succinic acid reached at the end of fermentation were 95% and 0.46 g (l h)⁻¹, respectively. These values were higher than those obtained using nontreated whey alone [93% and 0.24 g (l h)⁻¹ for 20 g l⁻¹ whey]. Continuous fermentation of A. succiniciproducens at an optimal dilution rate resulted in the production of succinic acid with high productivity [1.35 g (l h)⁻¹], high conversion yield (93%), and higher ratio of succinic acid to acetic acid (5.1:1) from nontreated whey. Received: 23 July 1999 / Received revision: 17 November 1999 / Accepted: 24 December 1999     

Whey Fermentation by Anaerobiospirillum succiniciproducens for Production of a Succinate-Based Animal Feed Additive

Anaerobic fermentation processes for the production of a succinate-rich animal feed supplement from raw whey were investigated with batch, continuous, and variable-volume fed-batch cultures with Anaerobiospirillum succiniciproducens. The highest succinate yield, 90%, was obtained in a variable-volume fed-batch process in comparison to 80% yield in a batch cultivation mode. In continuous culture, succinate productivity was 3 g/liter/h, and the yield was 60%. Under conditions of excess CO₂, more than 90% of the whey-lactose was consumed, with an end product ratio of 4 succinate to 1 acetate. Under conditions of limited CO₂, lactose was only partially consumed and lactate was the major end product, with lower levels of ethanol, succinate, and acetate. When the succinic acid in this fermentation product was added to rumen fluid, it was completely consumed by a mixed rumen population and was 90% decarboxylated to propionate on a molar basis. The whey fermentation product formed under excess CO₂, which contained mainly organic acids and cells, could potentially be used as an animal feed supplement.