bft112 introduction to engineering bioprocess …portal.unimap.edu.my/portal/page/portal30/lecture...

Bioprocess Engineering

EPT 112/3: Introduction to Engineering 1

BFT112 INTRODUCTION TO ENGINEERING

DR. RITA MOHD SAID

Outlines

EPT 112/3: Introduction to Engineering 2Creadit to: Nor Helya Iman Bt. Kamaludin

1. Introduction to biotechnology, bioprocess &bioprocess Engineering

2. Bioprocess Industries3. Product and Services by Biological Processes4. Fermentation Process5. The importance areas of Bioprocess

Engineering

Introduction to Biotechnology & Bioprocess Engineering


• Art and science of converting reactants(substrate) into useful products by the action ofmicroorganisms or enzymes.

Biotechnology

• Any process in which microbes or living organismsplay a vital role in getting transformation of thefeed into useful product.

Bioprocess

• Usage of engineering principles or terms toanalysis of and development and also design ofmethods using biological catalysts like enzymes,living cells, and genetically engineered cells

Bioprocess engineering

Biotechnology & Bioprocess


Biotechnology Bioprocess

A study about biologicalsystems or living organismsto make or modify productsor processes for specificuse, such as in agriculture,food production, andmedicine.

A branch ofchemical/processengineering, which dealswith the design anddevelopment of equipmentand processes that usebiological component suchas enzyme, bacteria, oryeast

biotechnology researchersmay develop a new strainof yeast for fermentationprocess

bioprocess engineers willdesign equipment andprocess condition to carryout the fermentationprocess in industrial scale

Bioprocess engineering/Biochemical engineering

The efficient utilization of physical, chemical and biologicalprocesses to convert raw materials into useful products, atminimal cost, with minimal energy consumption, and withminimal impact on the environment.

Involve the process for developing useful products by takingadvantage of natural biological activities.

Classical example include making alcoholic beverages – theyeast cells and nutrients (cereal grains) formed afermentation system in which the organisms consumed thenutrients for the growth and produced by-products (alcohol).


Bioprocessing•Because bioprocesses use living material, they offer several advantages over conventional chemical methods of production:

They usually require lower temperature, pressure, andpH.

They can use renewable resources as raw materials;and greater quantities can be produced with lessenergy consumption.


Bioprocessing

• In bioprocesses, enzymes are used to catalyze the biochemicalreactions by whole microorganisms or their cellularcomponents.

• The biological catalyst causes the reactions to occur, but is notitself changed.

• After a series of such reactions (which take place in largevessels called fermentors or fermentation tanks), the initial rawmaterials are chemically changed to form the desired endproduct.


Biologist and engineers differ in their approach to research


Biologist Engineers

• Have incompletebackgrounds inmathematics theories

• Posses a very goodbackground in the physicaland mathematical sciences

• Have very strong skills withrespect to laboratory toolsand interpretation oflaboratory data fromcomplex systems

• Typically unfamiliar with theexperimental techniquesand strategies used by lifescientists

Bioprocess Industries


Major area

Pharma-ceuticals

Environmental management

AgricultureFood

Chemicals/Energy

Product and Services by Biological Processes


Industry Product and Service

Chemicals/Energy Ethanol, acetone, butanol Organic acids (acetic, propionic and citric acids) Enzymes Perfumeries PolymersMethane (biogas)

Pharmaceuticals AntibioticsMonoclonal antibodies Steroids Vaccines

Environmental-management control or remediate toxic wasteWaste treatment

Food Diary products (cheese, yoghurts, etc.) Baker’s yeast Beverages (beer, wine) Vitamin B

Agriculture Animal feedsVaccinesMicrobial pesticides


Product and Services by Biological Processes

Fermentation Process


What is fermentation processes??

• is a metabolic process in which an organism converts acarbohydrate, such as a sugar, into an alcohol or an acid.

• For example, yeast performs fermentation to obtain energyby converting sugar into alcohol. Bacteriaperform fermentation, converting carbohydrates into lacticacid

Sources of fermentation process

Microorganism involved

• Yeast (saccharomyces cerevisiae)

• Fungi (aspergillus niger, rhizopus oryzae,etc)

• Bacteria (pseudomonas sp., bacillus subtilis, streptomycesolivaceus, etc)

Molasses, corn syrup, grain, fruit extract, agricultural wastes , etc.

Video: Fermentation Process


Industrial Fermentation

Definition:

The growth of microorganisms or cells in a large scale for producing

specific products

Equipment used:

Bioreactor

Size: up to 100 m3

Parameter to be controlled: aeration, pH

and temperature

Microorganisms and Products:

Yeast: bread, cheese, yoghurt, wine

Fungi: lactic acid (rhizopusoryzae), gluconic acid

(aspergillus niger)

Bacteria: Insulin (recombinant E.coli),

antibiotics (streptomyceserythreus)


FERMENTATION APPLICATION AND ITS

PRODUCT



Products of Fermentation

Production of Lactic Acid


Overview of Lactic Acid

• Lactic acid, also known as milk acid, is a chemical compound thatplays a role in various biochemical processes.

• Lactic acid is a carboxylic acid with the chemical formula (C3H6O3).

• It is the acid ingredient of sour dairy products, fermented fruits &vegetables and sausages.

• Many bacterial species produce lactic acid: Lactobacillus,Bifidobacterium, Streptococcus, Pediococcus and Leuconostoc.

• Lactic acid found in animals and humans has many functions, themost important is to the supply of energy in muscle tissue.


Lactic Acid Manufacture


Raw materials

• Carbohydrates

• Exp: corn, potato, molasses, whey

Exp: Production of lactic acid from whey

• Whey: waste product in manufacture of dairy products such as cheese

• Disposal of untreated waste may create environmental problems

• Whey can be converted from being a waste product to something more desirable.

Whey contain lactose, nitrogenous substances, vitamins and salts

Fermentation of lactose

Bacteria (Lactobacillus bulgaricus) utilise lactose and growth rapidly on whey

Capable of converting lactose to single end-product (lactic acid)


Application of Lactic Acid Fermentation

• Lactic acid fermentation is a biological process by which sugars suchas glucose, fructose, and sucrose, are converted into cellular energyand the metabolic byproduct lactate.

• Lactic acid fermentation is used in many areas of the world toproduce foods that cannot be produced through other methods.

• Two of the most common applications of lactic acid fermentationare in the production of:

yogurt sauerkraut (pickled cabbage)


Yogurt Production


• Yogurt is a semi-solid fermented milk product that originated centuries ago and has evolved from many traditional Eastern European (e.g., Turkish and Bulgarian) products.

What is yogurt???

• Animal’s milk: cow’s milk, etc.

• Other dairy products: concentrated skim milk, nonfat dry milk, whey, lactose.

• Sweeteners: glucose or sucrose, high-intensity sweeteners (e.g. aspartame)

• Stabilizers: gelatin, carboxymethyl cellulose, locust bean gum, guar, alginates, carrageenans, whey protein concentrate

• Flavours

• Fruit Preparations: including natural and artificial flavouring, colour

Ingredients

• Streptococcus thermophilus (ST)

• Lactobacillus delbrueckii subsp. bulgaricus (LB)

Starter Culture

Yogurt Manufacture


The milk is clarified and separated into cream and skim milk, then standardized with other dairy ingredients to achieve the desired fat and milk solids-not-fat content.

The various ingredients are then blended together in a mix tank equipped with a powder funnel and an agitation system.

The mixture is then pasteurized using a continuous plate heat exchanger for 30 min at 85° C or 10 min at 95° C.

The mix is then homogenized using high pressures of 2000-2500 psi.

Besides thoroughly mixing the stabilizers and other ingredients, homogenization also prevents creaming and wheying off during incubation and storage. Stability, consistency and body are enhanced by homogenization.

Once the homogenized mix has cooled to an optimum growth temperature, the yogurt starter culture is added.

A ratio of 1:1, ST to LB, inoculation is added to the jacketed fermentation tank.

A temperature of 43°C is maintained for 2-2.5 h under quiescent (no agitation) conditions.

The coagulated product is cooled to 5-22°C, depending on the product. Fruit and flavour may be incorporated at this time, then packaged.

The product is now cooled and stored at refrigeration temperatures (5° C) to slow down the physical, chemical and microbiological degradation.

Video: Yogurt Production


Production of Vinegar


Overview of Vinegar

• Vinegar is a liquid substance consisting mainly of acetic acid and water; the acetic acid being produced through the fermentation of ethanol by acetic acid bacteria.

• In food preparation procedures, it is a multi-purpose product as an ingredient and condiment.

• Outside of cooking, vinegar has medicinal, household cleaning, and agricultural applications.

• Vinegar is made from the oxidation of ethanol in an alcohol-containing liquid, such as wine, fermented fruit juice, or beer.


Types of vinegar:

depends on the kind of material used in the alcoholic fermentation


vinegar

Cider vinegar

Apple vinegar

Vinegar Manufacture


Raw materials

• Fruits

• Exp: grapes, apples, raspberries, cherries, lemons, etc.

Microorganism

• Acetobacter

• Gluconobacter

Two important steps in production of vinegar:


Acetic acid (vinegar) production

Acetobacter and Gluconobater oxidise ethanol in wine to acetic acid (vinegar)

Wine production

Sugar in fruits such as grapes are fermented by yeast to produce wines

Reaction involved:

C6H12O6 → 2CH3CH2OH + 2CO2

2CH3CH2OH + 2CO2 → 2CH3COOH + 2H2O

Zymomonas mobilis

Acetobacter sp.

Production of Penicillin


Overview of Penicillin

• Penicillin is a group of antibiotics derived fromPenicillium fungi.

• They include penicillin G, procaine penicillin,benzathine penicillin, and penicillin V.

• Antibiotics are natural substances that inhibits thegrowth of or destroys microorganisms

• Penicillin antibiotics are historically significantbecause they are the first drugs that were effectiveagainst many previously serious diseases, such assyphilis, and infections caused by staphylococci andstreptococci.


Penicillin Manufacture


Raw materials

• Molasses, corn steep liquor; wasteproduct from sugar milling corn

Microorganism used for penicillin production

• Mould species: Penicillium chrysogenum

• Can produce 1000 times more penicillin than previous method; original culture.

Major steps in commercial penicillin production


Preparation of inoculum

Preparation and sterilisation of medium

Inoculation of the medium in fermenter

Forced aeration with sterile air during incubation

Removal of mould mycelium after fermentation

Extraction and purification of the penicillin

Production of Enzyme


Overview of enzymes


What is enzymes??

• Proteins of higher molecular weight that act as catalysts

Function of enzymes

• To increase the reaction rates of chemical and biological processes

Characteristics of enzymes

~ specific

~ denatured by heat (at higher temperature)

~ extracted or precipitated by chemical solvents

such as ethanol

~ very effective biological catalysts

Industrial application of enzymes


Enzyme Application

Trypsin Anti inflammatory agent

Lysozyme Anti bacterial agent

Streptokinase Anti inflammatory agent useful for dissoluting blood clots

Urokinase Prevention of blood clots

Aspuraginase Anti cancer agent

Penicillinase Treatment of allergies against penicillin

Papain Tenderization of meat

Pectinase Clarification of fruit juices and wine

Chymosin Cheese production

Urease Conversion of urea into carbon dioxide and ammonium in dialysis process

The importance areas of Bioprocess Engineering

• Agriculture industryProduction of agricultural chemicalsfor and plant diseases, growth-stimulating a yield, production ofbiological insecticide and efficienttreatment and management wastes.

• Food industryIncreasing bioprocess efficiencies forfermen natural food additives, foodenzymes as process separation andpurification of the products,treatment wastes from food-processing industry.


• Renewable energy industry

Efficient use of renewable biomass resourcesof liquid fuel and chemical feedstocks.

• Chemical and pharmaceutical industry

Use of plant-cell culture systems to producesecondary metabolites or chemical substances


EXCERCISE1. Differentiate between bioprocess, bioprocess engineering and

biotechnology. (6 marks)

2. List FIVE (5) major areas involved in bioprocess industry and giveTWO (2) products produced from each industry. (15 marks)

3. What is meant by lactic acid fermentation? Give TWO (2)products mainly produced through this process. (5 marks)

4. List FOUR (4) areas the importance of Bioprocess Engineering.(4 marks)


bft112 introduction to engineering bioprocess …portal.unimap.edu.my/portal/page/portal30/lecture...

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