bio processing

BIO-PROCESSING OF FOODS

Vision and strategy

WHAT IS BIO PROCESSING

Like other applications of biotechnology, modern bioprocess technology is an extension of ancient techniques for developing useful products by taking advantage of natural biological activities.


When our early ancestors made alcoholic beverages, they used a bioprocess: the combination of yeast cells and nutrients (cereal grains) formed a fermentation system in which the organisms consumed the nutrients for their own growth and produced by-products (alcohol and carbon dioxide gas) that helped to make the beverage.

Although more sophisticated, today's bioprocess technology is based on the same principle: combining living matter (whole organisms or enzymes) with nutrients under the conditions necessary to make the desired end product.


This bio processing or a series of reactions take place in large tanks called fermentors and the process is known as fermentation.

Industrial microbiology uses microorganisms, typically grown on a large scale, to produce valuable commercial products or to carry out important chemical transformations. This process is commonly referred to as Fermentation

Further it can be classified into liquid state fermentation and solid state fermentation.

FERMENTATION PROCESSES

- Solid state: water content: 40~ 80%, mostly mold fermentation on agriculture products and food: rice, wheat, barley, corn and soya bean.e.g. rotary drum fermentator

- Submerged systems: water content > 95% e.g. bacteria, yeast.

FERMENTATION

EXAMPLESFermentation occurs in fruits, bacteria, yeasts, fungi, as well as in mammalian muscle.

Fermentation (tea) - used in the tea industry for the aerobic treatment of tea leaves to break down certain unwanted chemicals and modify others to develop the flavor of the tea

Fermentation (food) - the conversion of carbohydrates into alcohols or acids under anaerobic conditions used for making certain foods.

Fermentation (wine) – the process of fermentation commonly used in wine making

AREAS OF APPLICATIONBioprocesses have become widely used in several fields of commercial biotechnology-

Production of enzymes (used, for example, in food processing and waste management)

Antibiotics Food, beverages and Food Colors Vitamins Nutraceuticals And a multitude of value-added biomaterials As techniques and instrumentation are refined,

bioprocesses may have applications in other areas where chemical processes are now used.

LARGE-SCALE ENZYME PRODUCTION

Some examples

Protease (subtilisin, rennet)

Hydrolases (pectinase, lipase, lactase)

Isomerases (glucose isomerase)

Oxidases (glucose oxidase)

Produced using overproducing strains of certain organisms.

ENZYMES AND SOURCES Proteases

Overproducing strains of Bacillus, Aspergillus, Rhizopus, and Mucor.

PectinasesAspergillus niger.

LactasesYeast and Aspergillus.

LipasesCertain strains of yeast and fungi.

Glucose isomeraseFlavobecterium arborescens or Bacillus

coagulans

GROWING ENZYMES Cultivate the organisms producing

the desired enzymes. Production can be regulatedFermentation conditions can be

optimized for overproduction.

SEPARATION AND PURIFICATION

Disruption of cells Removal of debris and nucleic acids Precipitation of proteins Ultra filtration of the desired enzyme Chromatographic separation Crystallization Drying

SEPARATION AND PURIFICATION

The process depends on whether or not the enzyme is intra or extracellular.

Sometimes inactive (dead or resting) cells are used with desired enzyme activity in immobilized form.No separation and/or purification stepsReduces costs

TECHNOLOGICAL ADVANCES

Increasing in wider ranges of process conditions.

Enzymes grow in unusual environments (eg: deep ocean, salt lakes, and hot springs)

New enzymes and better control allow the use of enzymes in more extreme environments.

MAJOR USES

Cheese making (rennet) Baking Meat tenderization (papain,

trypsin) Brewing (trypsin, pepsin) Detergents (subtilisin Carlsberg) Tanning products Medical treatments of wounds

HEBEI SHENZHOU ANIMAL MEDICINE CO., LTD

Specialized manufacturer of zinc bacitracin in China.

GENENCOR INTERNATIONAL

Second largest developer and manufacturer of industrial enzymes.

Introduced the first industrial scale, recombinant enzyme in 1988.

Leader in the areas of protein engineering, expression/secretion technology and enzyme-substrate interaction.

NOVOZYMES Novozymes.com Largest producers of

enzymes. World Headquarter: Denmark (1941). More than 500 enzymes in over 130 countries.

PRODUCTION OF ANTIBIOTICS

Antibiotics are chemical substances produced by microorganisms to kill other microorganisms.

They are used in the treatment of infectious diseases.

RANGES OF FERMENTATION PROCESS

Microbial cell (Biomass)Yeast

Microbial enzymesGlucose isomerase

Microbial metabolites Penicillin

Food productsCheese, yoghurt, vinegar

Vitamins B12, riboflavin

Transformation reactionsSteroid biotransformation

FERMENTATION

Aerobic Anaerobic

AEROBIC FERMENTATION

Adequate aeration

Bioreactors- adequate supply of sterile air

In addition, these fermenters may have a mechanism for stirring and mixing of the medium and cells

Antibiotics, enzymes, vitamins.

ANAEROBIC FERMENTATION

In anaerobic fermentation, a provision for aeration is usually not needed.

Lactic acid, ethanol, wine

INDUSTRIAL FERMENTORS

VIEW LOOKING DOWN INTO A 125M3 STAINLESS STEEL FERMENTOR

FERMENTATION COULD BE:

Batch mode Fed batch mode (continuous)

SOME ANTIBIOTICS PRODUCED BY MICROORGANISMS

Antibiotic Producing microorganism Cephalosporin Cephalosporium acrimonium Chloramphenicol Streptomyces venezuelae Erythromycin Streptomyces erythreus Griseofulvin Penicillium griseofulvin Penicillin Penicillium chrysogenum Streptomycin Streptomyces griseus Tetracycline Streptomyces aureofaciens Gentamicin Micromonospora purpurea

MOA OF PENICILLIN

All penicillin like antibiotics inhibit synthesis of peptidoglycan, an essential part of the cell wall.

They do not interfere with the synthesis of other intracellular components.

These antibiotics do not affect human cells because human cells do not have cell walls.

SPECTRUM OF ACTIVITY

Penicillins are active against Gram positive bacteria

Some members (e.g. amoxicillin) are also effective against Gram negative bacteria but not Pseudomonas aeruginosa

PRODUCTION OF PENICILLIN

Penicillin was the first important commercial product

produced by an aerobic, submerged fermentation

First antibiotic to have been manufacture in bulk.

Used as input material for some semi synthetic antibiotics.

It is fermented in a batch culture

PRODUCTION OF PENICILLIN

When penicillin was first made at the end of the second world war using the fungus Penicillium notatum, the process made 1 mg dm-3.

Today, using a different species (P. chrysogenum) and a better extraction procedures the yield is 50 g dm-3.

There is a constant search to improve the yield.

THE YIELD OF PENICILLIN CAN BE INCREASED BY:

Improvement in composition of the medium

Isolation of better penicillin producing mold sp. Penicillium chrysogenum which grow better in huge deep fermentation tank

Development of submerged culture technique for cultivation of mold in large volume of liquid medium through which sterile air is forced.

THE MAIN STAGES OF PENICILLIN PRODUCTION ARE:

ANTI BIOTIC PRODUCTION PROCESS

FERMENTED FOODS

Foods that have been subjected to the action of micro-organisms or enzymes, in order to bring about a desirable change.

Numerous food products owe their production and characteristics to the fermentative activities of microorganisms.

Fermented foods originated many thousands of years ago when presumably micro-organism contaminated local foods.

FERMENTED FOODS

Micro-organisms cause changes in the foods which:Help to preserve the food,Extend shelf-life considerably over

that of the raw materials from which they are made,

Improve aroma and flavour characteristics,

Increase its vitamin content or its digestibility compared to the raw materials.

MAKING RED WINE

HISTORY AND ORIGINS OF SOME FERMENTED FOODS

s

Food Approximate yearof introduction

Region

MushroomsSoy sauceWineFermented milkCheeseBeerBread Fermented MeatsSourdough breadFish saucePickled vegetablesTea

4000 BC3000 BC3000 BC3000 BC2000 BC2000 BC1500 BC1500 BC1000 BC1000 BC1000 BC 200 BC

ChinaChina, Korea, JapanNorth Africa, EuropeMiddle EastMiddle EastNorth Africa, ChinaEgypt, EuropeMiddle EastEuropeSoutheast Asia, North AfricaChina, EuropeChina

FERMENTED FOODS

The term “biological ennoblement” has been used to describe the nutritional benefits of fermented foods.

Fermented foods comprise about one-third of the world wide consumption of food and 20- 40 % (by weight) of individual diets.

WORLDWIDE PRODUCTION OF SOME FERMENTED FOODS

Quantity (t) Beverage Quantity (hl)

Cheese

Yoghurt

Mushrooms

Fish sauce

Dried stockfish

15 million

3 million

1.5 million

300 000

250 000

Beer

Wine

1000 million

350 million

Food

BENEFITS OF FERMENTATION Benefit Raw

materialFermentedfood

Preservation Milk(Most materials)

Yoghurt, cheese

Enhancement of safetyAcid productionAcid and alcohol production

Production of bacteriocinsRemoval of toxic components

FruitBarleyGrapesMeatCassavaSoybean

VinegarBeerWineSalamiGari, polviho azedoSoy sauce

Enhancement of nutritional valueImproved digestibilityRetention of micronutrientsIncreased fibre contentSynthesis of probiotic compounds

WheatLeafy veges.CoconutMilk

BreadKimchi, sauerkrautNata de cocoBifidus milk, Yakult, Acidophilus yoghurt

Improvement of flavour Coffee beansGrapes

CoffeeWine

MICROBIOLOGICAL MINING: BIOLOGICAL LEACHING OF COPPER ORES

ALTERNATIVE ENERGY SOURCES USING MICROORGANISMS

BiomassBioconversion

Methane or ethyl alcohol

MICROBIOLOGICAL WASTE DISPOSAL

Sewage treatment plants Bioremediation- use of microbes to dispose

of chemical wastes 3 strains of microbes can Deactivate

Aroclor 1260- a toxic PCB Others detoxify cyanide and dioxin Use GMO microbes

ADVANTAGES OF BIO PROCESSING

Because bioprocesses use living material, they offer several advantages over conventional chemical methods of production: they usually require lower temperature, pressure, and pH (the measure of acidity); they can use renewable resources as raw materials; and greater quantities can be produced with less energy consumption.


Bioprocessing can increase the shelf life of foods by inhibiting the enzymatic deterioration of plant tissues.

It can enhance the texture, flavor and odor of foods. For example, the compound diacetyl is produced by various lactic acid bacteria during dairy fermentations (i.e.— cottage cheese, sour cream, buttermilk). This compound is responsible for the buttery aroma and taste typically associated with these products.

Fermentation helps food to be stored safely.

Fermentation allows humans to enjoy their favorite foods in a different way by creating a variety of flavors, textures, color, and appearance of some foods.

Fermentation is also used to create new energy sources such as ethanol.


The vitamin content of some foods can be increased.

Digestibility can be improved.

The toxicity of some foods (particularly oriental) may be decreased.

Some scientists believe that particular types of fermented milk products (i.e. acidophilus milk, yogurt) have a therapeutic value and can be beneficial in cases of alimentary disorders (i.e. constipation, diarrhea, etc.) and may even preclude the development and outgrowth of harmful bacteria.

CHALLENGES

In most bioprocesses, enzymes are used to catalyze the biochemical reactions of whole microorganisms or their cellular components. The biological catalyst causes the reactions to occur, but is not itself changed. After a series of such reactions (which take place in large vessels called fermenters or fermentation tanks), the initial raw materials are chemically changed to form the desired end product. Although it sounds quite simple, this procedure presents two major challenges.

CHALLENGES

First, the conditions under which the reactions occur must be rigidly maintained. Temperature, pressure, pH, oxygen content, and flow rate are only a few of the variables that must be kept at very specific levels. With the development of automated and computerized equipment, it is becoming much easier to accurately monitor reaction conditions and thus increase production efficiency

CHALLENGES

Second, the reactions result in the formation of many unwanted by-products. The presence of contaminating waste material often poses a two-fold problem: how to recover (or separate) the end product in a way that leaves as little residue as possible in the catalytic system (since enzymatic catalysts remain unchanged as they drive reactions, they can be used over and over again); and how to isolate the desired product in pure form.

The by-products or end products of fermentation include carbon dioxide, water, alcohol, lactic acid, and other acids. Sometimes these fermentation products create conditions unfavorable to microorganisms to a point where fermentation ceases. For example, fermentation comes to a halt when the percent of alcohol in a solution reaches about 12 percent.

FUTURE ASPECTThe many potential uses of biotechnology are developed through laboratory procedures that generally produce only small amounts of useful substances. As advances in bioprocess technology, particularly separation and purification techniques, are made, commercial firms will be able to economically produce these substances in large amounts, and thus make them available for use in medical research, food processing, agriculture, pharmaceutical development, waste management, and numerous other fields of science and industry.

VISION 2015: FOOD PROCESSING SECTOR EYES THE WORLD MARKET

Vijaylaxmi Kasotia discusses the various government initiatives which can help India exploit the emerging global opportunities in this sector

Making the sector attractive for both domestic and foreign investors.

Achieving integration of the food processing infrastructure from farm to market.

Having a transparent and industry friendly regulatory regime. Putting in place a transparent system of standards based on science.

REQUIREMENTS/STRATEGY

It is also the time to shift food processing industry from 'supply' to 'demand' driven sector by reducing costs,enhancing quality &safety systems, building markets, creating and promoting efficient supply chain, developing / inducting world class technology and management

It would require infrastructure development, food safety regulation, etc.

REQUIREMENTS/STRATEGY

We need a Back up of the research previously done on Bio processing Technology

We will have to search for some other potential microbes or the existing microbes should be further modified by genetic engineering

Last but not least an excellent team of innovative scientists from different fields like biochemistry, chemistry, microbiology ,chemical , biochemical and genetic engineering

WORDS OF WISDOM

“I imagine a future where our biological solutions create the necessary balance between better business, cleaner environment, and better lives.”

Dr. Swaranjit Singh Senior principle Scientist IMTECH, Chandigarh.

THANK YOU

bio processing

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