Biotechnology in the Food Industry

Biotechnology in the Food Industry
- From a Fermentation Technology Supplier Perspective
CLIB Forum 4th July 2013
Technology and Tradition
- Working for the Process Industry since 1878
History:
• In 1878 Heinrich Frings sr. founded a vinegar factory in Aachen.
• Acetic acid fermentation at the scientific-engineering level is initiated
by Heinrich Frings jr.
• At the beginning of the 20th century Frings developed into a
constructor of fermentation and other process systems.
• Frings processes have evolved through several generations of
technologies.
Frings today:
• Headquarters in Bonn, Germany
• International constructor of plants for food technology‚ environment
technology and biotechnology,
• 80 employees (worldwide)
• Largest project realized by Frings: 23 Mio. €
Markets and Technologies
- Actual Product Portfolio of FRINGS
Key Technologies and System Solutions for the Fermentation Industry:
Food
Filtration
Biotechnology
Separation
Environment
Aeration
Automation
Others
Mixing
Fermenter Technologies
- Sizes of FRINGS Fermenters
Volumen Range: 500 mL – 500.000 L
Lab Scale Fermenter
PROREACT 5 P
Pilot Fermenter
PROREACT 75 P
Large Scale Fermenters
PROREACT 300 B
Fermenter Technologies
- Hygienic Standards
FRINGS “Package Units” and Fermentation Groups for a Wide Range
of Food Applications:
Fermentation Groups with
low hygienic standard
(FRINGS HEJP Fermenter
for Baker‘s Yeast)
FRINGS Systems with CIP and SIP
(PROREACT B Fermenter)
Units for Recombinant Cells
with highest standards
(PROREACT G Fermenter)
Industrial Bioprocesses
- Block Diagram in Biotechnology
Up-Stream
Up-Stream
CIP/SIP
Raw Material-/
Mediapreparation
Sterilisation
Down-Stream
Down-Stream
Fermentation
CIP/SIP
Separation/Isolation
Purification/Blending
Confectioning/Packaging
Product
Waste Disposal
Products made with Biotechnological Methods
Biotechnology related with Food Industry
- Product Clusters
1. Fermented beverages/Fermented liquid foods
2. Classical food additives ‚with E number‘
3. Classical food additives ‚without E number‘
4. Special yeast products
5. Technical enzymes
6. Vitamins
7. Biogenic nutraceuticals/special food additives
8. Algae biotechnology
9. (Bioenergy)
10.(Bioplastics production)
11.(Biopesticides)
Biotechnology related with Food Industry
- Product Clusters
1. Fermented beverages/Fermented liquid foods
Beer, wine, fermented milk products, vinegar, other lactic acid fermentates,
gluconic acid fermentates, soy sauce, kombucha, kwas, ….
2. Classical fermented food additives ‚with E number‘:
MSG, citric acid, gluconic acid, xanthan, (carotinoids), (alginate), …
3. Classical food additives as ‚fermentates without E number‘:
Fermentates as flavor enhancers which are produced without purification
with natural microorganisms and which therefore, under certain conditions,
do not require declaration under an E number.
Biotechnology related with Food Industry
- Product Clusters
4. Yeast products
Baker‘s yeast, starter cultures, yeast extracts, ‚savoury‘ yeasts, ‚detoxin‘
yeast, recombinant yeasts for enzyme production, …
5. Technical Enzymes:
Enzymes for dairy, baking, sugar industry, agro-enzymes, lipases,
proteases, amylases, pectinases, phytase, asparaginase, …
6. Vitamins
Riboflavin (B2), cyanocobalamin (B12), vitamin C, …
Biotechnology related with Food Industry
- Product Clusters
7. Biogenic nutraceuticals/special food additives:
Amino acids and intermediates like adenosylmethionine, aspartame, antioxidants, omega 3/6 fatty acids, special sugars like fucosyllactose,
exopolysaccharides, probiotics, algae products, …
8. (Bioenergy)
9. (Bioplastics production)
10. (Biopesticides)
Other Purposes:
Energy Integration, Packaging,
Agriculture, Added value
byproducts, …
Aspects of Food Industry Regulations
- Restrictions for Innovative Products
Excerpt of Regulations for the Food Industry (in Germany):
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Lebensmittel- und Futtermittel-Gesetzbuch LFGB
Verordnung Lebensmittelhygiene 2004/852/EG
Lebensmittel Kennzeichnungsverordnung LMKV
Zusatzstoff-Zulassungsverordnung ZZulV
Zusatzstoff-Verkehrsverordnung ZVerkV
Verordnung Nahrungsergänzungsmittel 2009/1170/EG
Richtlinie Nahrungsergänzungsmittel 2006/37/EG
Richtlinie Nahrungsergänzungsmittel 2002/46/EG
Verordnung Enzyme 2008/1332/EG
Verordnung Lebensmittelzusatzstoffe 2008/1333/EG
Verordnung Aromen 2008/1334/EG
Verordnung GMO 2003/1829/EG
Verordnung Biologische Produkte 2007/834/EG
Novel Food Verordnung 1997/258/EG
…
Example 1
- Classic Food Biotechnology -
Baker’s Yeast Production
and other Products produced with Yeasts
Baker’s Yeast
- Starter for the Bread Baking Process
General Process Chain:
Flour
Verunreinigungen
Enzymes, Blends, Salts
Water, (Baking Powder)
Heat
Heat
Screening
Mixing
Kneading
Leavening
1. Rising
Proofing
2. Rising
Baking
Bread
Baker‘s Yeast
Water
Yeast Production
- General Process Chains for Different Products
Molasses
Chemicals
Molasses preparation
Molasses separation
Lab Culture
Saccharomyces
cerevisiae
Pure-/Seed Yeast I/II
Yeast Separation
Yeast Milk 4-6 oC
Commercial Yeast
Yeast Separation
Yeast Filtration
Yeast D27-D32
Autolysis
Separation
Evaporation
Spray Drying
Yeast Extracts
Granulation
Moving Bed Drying
Dry Yeast
Extruder
Cutter
Block Yeast
Baker‘s Yeast Technology
- Large Scale Bulk Production
CFD for Aeration Design
Typical Yeast Plant, FRINGS
Product:
Mix of fresh and dry yeast
Production Capacity: 3.000 – 8.000 to/a
Fermenter Volume:
240 m3
Design:
static
Mixing and Aeration System
FRIBORATOR 24000, FRINGS Bonn
Air Flow: 8.000 m3/h
Power
315 kW
Yeast Technologies
- Use of Yeasts for Different Food Related Products
Yeasts for the Production of Enzymes in the Food and Feed Industry
Yeast
Saccharomyces cerevisiae
S. carlsbergensis
Kluyveromyces lactis
Kluyveromyces fragilis
Pichia pastoris (GMO)
Product
Invertase, Galactosidase
Invertase
Lactase, Chymosin
Lactase, Inulinase, Invertase
Phytase
Yeasts for the Production of Food
Yeast
Saccharomyces cerevisiae
Zygosaccharomyces, Candida spec.
Phaffia rodozyma
Kluyveromyces lactis
Saccharomyces carlsbergensis/cerevisiae
andere
Kluyveromyces marxianus
Candida (Torula) utilis
Saccharomyces spec.
Product
Baker’s Yeast
Soy Sauce, Kombucha
Carotinoids
Whey Fermentation
Beer, Wine Brewing
Kefir, Raw Sausage,
Savoury yeast (MSG, 5’GMP, 5’IMP)
Example 2
- Classic Food Biotechnology -
Vinegar Production
and other Products Produced with AAB
Vinegar Production
- Wine and Bulk Vinegars
Sugar-/Starchbased
Raw Material
Enzymes
Wine
Mashing
Fermentation
Filtration
(Dilution)
Wine Vinegar
Pressing/Extraction
(Saccharification)
Mashing
Alcohol fermentation
Yeast separation
Acetic Acid Bacteria
Yeast
Rectification
Ethanol
(Mashing)
Fermentation
Filtration
Dilution
Bulk Vinegar
Slop
Water
Vinegar Production
- Traditional and Modern Production
Traditional European
Vinegar Fermentation
Traditional Chinese Solid
State Vinegar Fermentation
Modern Acetic Acid Vinegar
Fermentation Plant, KÜHNE Germany
Production Capacity 45.000 to/a
Vinegar Production
- Increase of Performance Data
Acid concentrations achieved by Frings Acetators
25
24
23
22,3
22
acetic acid concentration [% w/v]
22
21
21
19,8
20
20,5
19
20
19
18
16,5
17
17
16
16,2
15
15,5
15
14,5
15
14,5
14
13,5
14
13
12,5
13
12
11,5
12
11
19
17,5
18
11
10
year
Normal process
DSHS process
Historical Data of ACETATOR Processes
SSHS process
Normal process future
20
20
20
15
20
10
20
05
20
00
19
95
19
90
19
85
19
80
19
75
19
70
19
65
19
60
19
55
19
50
10
Vinegar Fermentation
- Main Factors who have increased Performance
Microbiology:
• Evolutionary Screening of Acid Resistant Mutants
• Development of Special Nutrients and Micronutrients
Bioreactor Design:
• New Methods for Fermenter Design  higher kLa
Processes:
• Optimization of Repeated Fed Batch Processes
• Gradients of Relevant State Variables (T, CS, …)
Automation:
• Highly Reproducible Automatic Charge and Discharge Control
• Exact Flow Count of Transferred Liquids and Online Control of EtOH
Expert Knowledge:
• Operational Skills/Training
Potential of Processes with AAB
- for Different Industries
Vinegar Technology
-Wine and Fruit Vinegars
-Rice and Cereals Vinegars
-Spirit Vinegar
-Food Ingredient
-Pickled Vegetables
-Ketchup and Sauces
-Vinegar Drinks
…
Food and Beverage
Biotechnology
-Fermented Softdrinks
-Food Ingredient
-Vitamins
-Special Sugars
-Kombucha Similars
-Thickeners
…
-Cosmetic Industry
-Neutraceuticals
-Pharmaceuticals
-Polymers
-Fine Chemicals
-Fragrances
-White Biotechnology
-…
Substrate Spectrum of AAB
- Metabolism of Acetic Acid Bacteria
Ethanol
Acetaldehyde
Acetate
Ox-PP
Glucose
Ox-PP
Gluconate
Lactate
Pyruvate
Glucose
Gluconate
UQH2
2-Keto-gluconate
5-Keto-gluconate
D-Sorbitol, Gluconate, Glycerol
2,5-Diketo-gluconate
L-Sorbose, 5-Ketogluconate, DHA
Respiratory
chain
D-Sorbitol
L-Sorbose
D-Sorbitol
UQH2
Pyruvate
Ethanol
Acetaldehyde
D-Fructose
Ox-PP
Acetate
D-Fructose
Unknown
substrates
Unknown
products
Flavin
PQQ
Unknown
substrates
Unknown
products
Unknown
substrates
Unknown
products
Processes with AAB
- for Different Industrial Production Purposes
Product
Process
Remarks
Dihydroxyacetone
(Tanning Agent)
Fed Batch
- Product Concentration > 200 g/L
Erythrulose
(Tanning Agent)
Fed Batch
- pH control
- Low Temperature preferred
Ascorbic Acid (Vitamin C) and other
Acid Intermediates (L-Sorbose
2,5-Diketogluconate
2- and 5-Ketogluconates,..)
Batch
Fed Batch
- Direct Route under Development
Miglitol (Anti Diabetic Drug)
Intermediates (6-Amino-L-Sorbose, Nprotected)
Two Step Process:
1. Cell Growth on Sorbit
2. Disc Stack Separation
3. Whole Cell Batch Catalysis
- High Integral Oxygen Demand
Fruit Esters/Acids (Aroma Industry)
Fed Batch
- ATEX Requirements
Gluconic Acid Bases (Food and
Beverage Ingredient)
Batch/
Sequential Batch
- Isolates from Kombucha
Acetic Acid
(Vinegar, Glacial Acid)
Batch
Repeated Batch
Repeated Fed Batch
- Autosterile Process
- Highly Sensible to Lack of Oxygen
- Product Concentration > 200 g/L
Scale Up/Down
- AAB Fermenter for R&D
Industrial AAB Vinegar
ACETATOR
Lab-/Pilot-Vinegar ACETATOR
Industrial Sterile AAB
PROREACT
Mini-PROREACT
Pilot-PROREACT
Example 3
- Biorefinery and Food -
Added Value Byproducts in
1st Generation Biorefinery
Biorefinery
- With Added Value Byproducts for Food and Feed Industry
Wheat
Grinding
Mashing
Wheat bran
Gluten
Gluten Separation
Liquefaction
Enzymes
Separation
Saccharification
Enzymes
Alcohol fermentation
Yeast separation
Compression
Yeast Propagation
Yeast
Stillage
Drying
DDGS
Rectification
Dehydration
Bioethanol
CO2
Biorefineries
- With Added Value Byproducts for Food and Feed Industry
Plant erected in Kasachstan in 2006 by FRINGS Austria
Biorefineries
- With Added Value Byproducts for Food and Feed Industry
Frings Biorefinery for the Production of Bioethanol, CO2, Glutenprotein, Yeast
and DDGS with Integrated Water Management System
Production Capacity Ethanol: 200.000 L/24 h
Example 4
- Modern Food Biotechnology –
Development of
Enzyme Processes
(in Germany)
Enzyme Technology
- Food Enzymes in Use or Under Development
Food
Enzymes
Purposes, Improvements
Bread and
Bakery
Products
Amylase, Lipase, Protease,
Hemicellulase, Xylanase, Glukoseoxidase,
Hexoseoxydase, Lipoxygenase,
Transglutaminase, Asparaginase, …
Optimisation of dough, shorter leavening,
baking process, freezing, pumping,
acrylamid reduction, …
Sweets
Invertase, Lactase, Isomerase, …
Sweetening, improvement of rheology,
liquifaction of „pralines“, lactose hydrolysis
Starch
Amylase, Pullulanase, Xylanase,
Glucooxidase, Isomerase, CGtase…
Saccharification, sweetening, modified
starch, fat simulation, dextrins, water
binding, ..
Dairy
Lactase, Transglutaminase, Protease, …
Lactose hydrolysis, aroma modification,
fat simulation, texture modification, …
Eggs
Katalase, Glucoseoxidase, …
Conservation, colour reduction, …
Meat and
Sausage
Protease, Transglutaminase, …
Enhancement of maturation, better
texture, „meat glue“, …
Proteins
Protease
Foam, viscosity, milk imitation, soy sauce,
savoury,
Flavor
Lipase, Protease, Pektinase, Pektinesterase
Artificial cheese, butter and meat flavor,
citric flavor, colour extracts, …
Noodles
Lipase, Hemicullase, Xylanase
Texture and colour improvement, increase
of hydrophobicity,
Enzyme Processes
- Fermenter for Lab- and Pilot Enzyme Development
PROREACT P Seed Train 10.000 L
PROREACT P Multi + Seed Train 150 L
Remark: Specific Design for Pichia pastoris fermentation with methanol as Inducer
Enzyme Processes
- Fermenter for Lab- and Pilot Enzyme Development
PROREACT P for Enzyme Development at c-LEcta, Leipzig
Thank You very much
for Your Attention