Production of Vinegar By Submerge Fermentation

Author Dr. Ahmed Jawad Ali

Reactions
C6H12O6 ----2 C2H5OH +2 CO2 GLUCOSE Ethanol Carbon Dioxide
C2H5OH+ O2 ---- CH3COOH+ H2O Ethanol Acetic Acid

General Information

Type of Bacteria : Aceto-bacter 1 Lit. (0.79 kg) Ethanol1.036 kg Acetic acid. Actual yield 65-90% Temp. of Fermentation : 15 34 C

Methods of Manufacture
1- Orleans Process The oldest and also the best for the production of table vinegar Barrels of approximately 200-liter capacity are used as the containers in this process Air is admitted to the barrels through 1 holes-one usually at each end of the barrel, which is placed on its side-above the vinegar medium. The acetic acid bacteria form a thin film on the surface of the solution, and this film later becomes quite thick and gelatinous.

Methods of Manufacture

Each barrel is filled about 1/3 full with a good grade of vinegar, which constitutes the starter, and 10 to 15 liters of ethanol are added. At weekly intervals for 4 week, the same amount of ethanol is added to the barrel. When 5 week have passed, 10-15 liters of vinegar are withdrawn from the barrel, which is now about filled, and the same amount of ethanol is added. The operation may be repeated, thus becoming a slowly continuous process.

Orleans Process

Methods of Manufacture
2- Modified Orlean Process A light grating of wood may be floated on the liquid medium to support the bacterial film and prevent it from breaking up and sinking. 3- quick vinegar process the alcohol bearing aqueous substrate is allowed to, trickle over wood shavings carrying the microorganisms or like carriers having a large surface area exposed to ambient air

Industrial Technology Development Institute/ Food Processing Division

Philippines

Industrial Technology Development Institute/ Food Processing Division Philippines

FEATURES OF FPD ACETATOR: Produce naturally fermented vinegar Designed to accelerate the traditional fermentation process of producing vinegar Easy to operate Can be set-up in the countryside and requires minimum processing area Can be operated on a minimum initial volume of operation Start-up time is at least 7 days Product can be drawn out daily from the fermentor Can convert most sugary materials to vinegar (e.g. coconut water, pineapple wastes, sugar cane, dried mango spent syrups, etc.)

QUICK VINEGAR PROCESS

QUICK VINEGAR PROCESS

Methods of Manufacture
Submerge Fermentation Process

During 1949-1953 Hromatka et al. produced Acetic Acid from alcohol by submerged fermentation process in lab. Scale. In about 1960 Heinrich Frings/Germany apply this process commercially in a submerge bioreactor called Acetator. Aeration is critical, interruption of the air supply for as long as a minute will completely stop acetification.

Methods of Manufacture
Submerge Fermentation Process

The Acetator generally produces about 6-9% acidity and the product is diluted to 4-6% depending on the vinegar standard. The vinegar is usually matured in full, closed vats of wood or stainless steel...for periods of up to a year. During this time, the vinegar develops its characteristic flavor and aroma and some unstable colloids settle out.

The Acetator

Submerge Fermentation Process

Comparison between Quick & Submerge Process

Quick Process (Generators) Submerge Fermentation (Acetator)
Small

Bioreactor Volume

Very Large (30 times theAcetator)

Start-up Time

2-3 months

3-5 Days

Residence Time for Complete Conversion

7 days

1-2 days

Operational Problems

Blockage of Liquid distributed

No problems

IRAQI PATENT No. 3030/2002

Pilot Plant

Semi-Commercial Plant

Process Flow Diagram (PFD)

The Aeration Spider

Mechanical foam separator

Mechanical foam separator

Foam Breaker
B

A C

Top View
Impeller
Nozzle Desceiption

Impeller

Seal

D Polly Motor

A B C D E F G&H

Air Inlet Air Outlet Liquid Inlet Liquid Outlet Wheel Pipe Diameter Manhole Level Taps

Front View

Bioreactor Data Sheet

Model 3

F B

G A C Foam Foam Draft Tube

Top View

Aerator Impeller
Nozzle Desceiption

No Seal

Impeller H D Polly

A B C D E F G&H

Air Inlet Air Outlet Liquid Inlet Liquid Outlet Wheel Pipe Diameter Manhole Level Taps

Front View

Bioreactor Data Sheet

Model 2

Benefits
1. 2.

3.

4.

5.

6. 7.

One step clarification Eliminates diatomaceous earth Water-white distilled vinegar products Product quality less than 1 NTU Excellent post-bottling haze stability 99+% product recovery with diafiltration Compact design Easy-to-install and operate

Principles of Operation

Type GMJ-5E Cabinet type Soy/Vinegar Sterilizer