FERMENTATION INDUSTRIES

Presented: LLONA, EMERALD E.

What is Fermentation?
Fermentation is a metabolic process that
produces chemical changes in organic substrates
through the action of enzymes. In biochemistry,
it is narrowly defined as the extraction
of energy from carbohydrates in the absence
of oxygen.
Louis Pasteur
• Louis Pasteur was a French biologist, microbiologist
and chemist renowned for his discoveries of
the principles of microbial fermentation.
• He showed that fermentation is directly caused
by the life processes of minute organisms.
How it’s made
• Fungi feeds upon organic materials. This feeding
interests the manufacturer, if he supplies to
certain fungi the necessary fundamental energy food,
together with the other needed nutrients, then
these micro vegetative organisms will not only
grow and multiply but will change the
food-into other chemical substances.
Important Chemical Processes of
Fermentation
• Oxidation – loss of electrons eg. alcohol to
acetic acid, sucrose to citric acid, and
dextrose to gluconic acid
• Reduction – gain of electrons eg. aldehydes to
alcohols, acetaldehyde to ethyl alcohol and
sulfur to hydrogen sulfide
Important Chemical Processes of
Fermentation
• Hydrolysis – Large molecules is broken apart to
produce smaller molecules, energy is released,
water is used to split the bond.
• Esterification- When a carboxylic acid is treated
with an alcohol and an acid catalyst,
an ester is formed (along with water).
5 basic pre-requisite of fermentation
• A microorganism that forms a desired end
product. This organism must be propagated and
capable of maintaining biological uniformity.
• Economic raw materials for the substrate
• Acceptable yields
• Rapid fermentation
• Product that is readily recovered and purified
Critical Factors of Fermentation
• pH
• Temperature
• Aeration- Agitation
• Pure-Culture Fermentation
• Uniformity of Yields
Industrial Alcohol
Distilled ethyl alcohol (C2H5OH), normally high proof,
Completely denatured alcohol, and Specially denatured alcohol
It is usually distributed in the form of pure ethyl alcohol,
• Completely Denatured Alcohol- is commonly exempt
from excise duty levied on drinkable alcohol
and is used as a solvent or fuel.
• Special Denatured Alcohol- used in an aftershave
lotion,eg. may kill if swallowed.
Uses and Economics
• Tax-paid pure alcohol is used only
for medicinal, pharmaceutical, flavouring,
or beverage purposes.
• Alcohol is second only to water in
solvent value and is employed in nearly
all industries
• Alcohol is the raw material for making chemicals.
Uses and Economics
• During WORLD WAR II Alcohol was used
as supplemental raw material for butadiene.
• In petroleum-poor countries it is economical
to mix alcohol in with gasoline in
order to conserve product.
Uses and Economics
Raw materials from which ethyl alcohol may
be made fall into four general classifications:
1. Saccharine Materials
2. Starchy Materials
3. Hydrocarbon Gases
4. Cellulosic Materials
Uses and Economics

Cereal Grains
Molasses

Woods, Agricultural Residue

Hydrocarbon gases
Uses and Economics
• Molasses being almost unobtainable, during the World
War, manufacturers turned to wheat and corn.
• Fermenters used the cheapest raw material
Manufacture of Industrial Alcohol
Reactions
• The principal reactions in alcohol fermentation are
Equation of inversion:

• Equations of fermentation:
Reactions
• Toward the end of a fermentation, the
acidity and glycerine increase. Neuberg's third equation
may account for this.

• There is always found in alcohol fermentations a small amount of

glycerine
Energy Requirements, Unit Operations,
Unit Processes.
• Shipment of raw material may involve tank-car
movement of molasses.
• Plant procedures require steam heating, power, and water.
Making of Industrial Alcohol
Molasses into Saleable Alcohol
• It must be diluted first to a concentration
• Pumped to a large steel fermentor.
• Closed in modern plants.
• Ammonium salt and sulfuric acid are added.
• Selection of the inoculating yeast
• Sterilization of the dilute molasses
• Addition of the nutrients
• Addition of pH and temp
• Cleaning and Sterilizing the yeast
Molasses into Saleable Alcohol
• Fermentation is exothermic and so cooling by
outside sprays is frequently used.
• most favorable temperature varies
70oF for starting
100oF at the end
• Four days are allowed for a fermentation
cycle, though usually 36 to 50 hours are used
Molasses into Saleable Alcohol
• Split sucrose into d-glucose and d-fructose
• Gives off enzyme called invertase
• and zymase
• When Starchy materials are used, it
is necessary to convert yeast into
Monosaccharide using malting process.
• Fungal amylase- replacement
Molasses into Saleable Alcohol
• The liquor in the fermentor after the
action is finished is called beer.
• Distillation is used to separate alcohol
• The beer is pumped to the upper sections
of the beer still, after passing several heat exchangers
• Beer passes down the beer column, loses
its lighter-boiling constituents.
Molasses into Saleable Alcohol
• In the third column the alcohol is
brought to strength and finally purified.
• Alcohol-water mixtures are rectified to increase
the strength of the alcohol component
Absolute or Anhydrous Alcohol
• Anhydrous alcohol was made by absorbing the
5% of water present in 95% industrial alcohol,
using quicklime, with subsequent distillation.
• This process has now been superseded largely
by improved chemical engineering unit operations of
distillation and extraction involving a third component.
• has led to lower cost dehydrating operations.
• The water in 95% alcohol is removed
technically by either of two principal methods:
(1) Dehydration by distillation with a third component
(2) Dehydration by counter current extraction
• Anhydrous alcohol comes out the top of
the extraction column
Beers, Wines and Liquors
Uses and Economics
• The making of fermented beverages was discovered
by primitive man and has been practiced
as an art for thousands of years.
• Many millions of barrels of alcoholic beverages
are manufactured in the United States each year.
Raw Material
• Grains and fruits supplying carbohydrates are the
basic raw materials.
• The variety of grains and fruits employed
is wide, changing from country to country
or from beverage to beverage.
• The world's chief raw materials for fermentations
are the cereals, corn, barley, and rice, together
with the grape.
Making of Beer
What’s in a Beer?

•BARLEY – the body & soul of beer

• YEAST – the life of beer
• HOPS – the spice of beer
• WATER – the integrity & purity of beer
• ADJUNCTS – Additive grains like rice or corn, fruit or spices
Making Beer -a three step process

• Malting- converts raw grain into malt.

• Brewing- steeping a starch source water and fermenting
the resulting sweet liquid with yeast.
• Fermentation
Malting
• Takes place in malt houses
• Occasionally in a brewery
• Controlled germination of barley
• Moisture
• Temperature
• Carbon dioxide
• Goal
• Produce enzymes useful for brewing
• Amylases
• Proteases
Malting
• Soaking the grain
• Allow for controlled germination
• Maximum enzyme production
• Minimum enzymatic activity and plant growth
• Kiln drying
• Stop germination
• Stabilize malted barley
• Impart color and flavor
• Light malt, dark malt, amber malt, black patent malt
Brewing
• Functions:
• Enzymatic conversion of starch to maltose,
proteins to amino acids

• Extraction of hop flavors and aromatic compounds

• Sterilize maltose/hop flavor solution

Brewing
• Milling of malted barley
• Careful cracking of malted barley
• Shatter endosperm
• Keep husk in large pieces

• Adding water

• Controlled temperature for enzymatic action

 Mash Tun
The mash tun is a vessel in which the
milled malted barley is mixed with water
and the enzymes are allowed to degrade
the starches and proteins into substrates
that the yeast can utilize during
fermentation.
Mash
• These photos show the milled
malted barley being mixed with
warm water. The enzymes
convert the starch to maltose and
the proteins to amino acids creating
what is known as sweet wort.
 Filtering
The sweet wort is separated from the
spent barley by a filtration step known
as Lautering. The barley husks serve
as the primary filtering material.
Here, the remaining spent grains are
being removed from the sweet wort
with this screen.
Mash Tun with used Mash
• These are the spent malt that acted as a filtering bed for the sweet wort.
Sweet Wort
Kettle
• Sweet Wort
• Bring to boil
• Add hops
• Extract flavors (bitter acids)
and aromatic compounds
• Sterilizes hopped wort
Fermentation Tanks
• After the yeast is added to the hopped
wort, fermentation of the maltose to ethanol
occurs in these tanks.
Adding yeast to the fermenter
Blow-off hoses on fermentation tanks
• Fermentation produces both ethanol and carbon dioxide.
The carbon dioxide is allowed to vent
out through these blow-off hoses whose
ends are immersed in a tank of
water, producing an air-lock and preventing
oxygen from entering the fermentation tanks.
Cleaning fermentation tanks
• Cleanliness is critical in producing quality beer.
• Microbial contamination can result in off flavors
and aromas.
 Making of Wines

“To Serve with Knowledge & Pour with Skill”

What is Wine?

• Wine is the fermented juice of any

fruit or vegetable.
• You can make wine from almost any
organic substance that contains sugar
and water typically found in fruits and
vegetables.
5 Basic Type of Wine
• Five basic types of wine are:
• Red Wine
• White Wine
• Rose Wine
• Sparkling Wine - carbonated
• Fortified Wine - high alcohol content
Why use grapes to make wine?
• Winemaking is the art of making wine.
• It involves working with grape juice and
yeast to achieve a balance of wine qualities:
• sweetness
• acidity
• alcohol content

• Wine from grapes possesses a good combination

of the qualities.
How is wine made?
• It starts in the vineyard at harvest:
• Wait until the grapes reach the proper maturity
• The riper the grapes the sweeter the wine
• Ripening will depend on many factors, such
as the temperature, amount of sun and
rainfall, availability of nutrients. Manual picking

• The grapes can be harvested manually or

by mechanically.

Mechanical picking
 How is wine made?
• After harvesting:
• The grapes undergoes destemming and crushing.
• There are a variety of presses that are
used to produce the juice, which is called “must”.
• The sugar in the wine is used by the yeast
Crusher
to produce ethyl alcohol and carbon dioxide gas Small Bladder Press
• The type of yeast can affect the qualities and
other compound of the wine.

Large Rotary Press

How is wine made?
• Fermentation and Aging:
• The must is transferred to large, refrigerated Active Yeast Cells
stainless steel tanks where fermentation happens.
• The wine is then transferred to oak barrels for
aging for 6 to 24 months.
• The wine maker will then blend the various
lots of wine to produce a finished Fermentation Tanks
wine ready for bottling.

Barrel aging
Barrel filling
 Bottles being filled

How is wine made?

Bottling line
• Bottling and Cellaring:
• After all the process the wine is
transferred to bottles.
• Most wine is consumed within three
years of bottling.

Small in-home cellar

Large Commercial Cellar

Differences in making red & white wine
White Wine:
• Harvested and pressed.
• Only must is fermented
• Some, such as Chardonnay, is aged in oak
barrels.
• Wine is bottled
• Most white wines are not bottle aged but
consumed with in 3 years of bottling.
• However, an exception is particularly fine
wines made from Chardonnay and
Champagne
Red Wine
• Harvested and crushed.
• Includes the skin during fermentation
• Commonly aged in oak barrels for 6 to 24
months.
• Wine is bottled.
• Many red wines are ready to drink after
bottling.
• However, some red wines, such as
Cabernet Sauvignon, will benefit with
some bottle age.
Making blush & sparkling wines
Blush Wine:
• Red grapes are harvested for Rose or
Blush wine.
• The must is left with skin for a short time.
• Must is fermented in stainless steel tanks.
• Fermentation is stopped if sweet wine is
desired
• The wine is bottled
• Blush wines are not commonly bottle
aged but consumed within 3 years of
bottling.
Champagne (Sparkling) Wine:
• Grapes for sparkling wine are harvested and
pressed.
• It is fermented like a white wine.
• More sugar and yeast is added to the wine.
• The wine is bottled.
• The additional sugar and yeast produce carbon
dioxide, which carbonates the wine.
• The second fermentation is stopped.
• Sparkling wines are made to drink early.
Making fortified wine
• Fortified Wine:
• Grapes for fortified wines are harvested
like others
• The must may be handled in different
ways to intensify the flavor
• Most fortified wines have an addition of
alcohol (brandy)
• Many fortified wines will benefit with bottle age.
Sugar and Organic Acids
• Primary compounds of interest are sugar and
organic acids (sweet and sour).
• As grape ripens it accumulates sugar.

• Organic acids decline during ripening, it is

due to dilution and respiration.

• Hot Climate: High sugar Low Acid

Cool Climate: Low sugar High Acid
Sugar Measurement
• Sugar is the most abundant compound(s) found
in berry.
• Abundance allows indirect methodology for measurement.
Unit Brix = % or g/100 mL)
• Hydrometer used in winery to monitor fermentation
Sugar and Ripeness
• Typically grapes will accumulate up to 25-26 Brix.

• Winemakers often will allow crop to hang

on vine waiting for flavors to develop.

• During this hang time the berries tend

to lose weight.
Organic Acids
• Principal organic acids are tartaric acid and
malic acid.
• Tartaric acid is the most abundant. Responsible for the
tart taste of wines
• Stable to microbial fermentation but forms
insoluble salts with potassium.
• Malic acid can be metabolized by yeast and bacteria.
Responsible for the tart taste of green apples
Organic Acid Measurement
• Measured by titrating with a base of
known concentration in the presence of a
chemical indicator with a known pH end point.

• This measurement called titratable acidity (TA).

• Concentrations range from 8.0 g/L to 6.5 g/L

pH ranges from 2.8 to 4.0.

White wine 3.0-3.3 Red wine 3.2-3.4

 Other Parameters
• Anthocyanin and tannin content in red grapes.

• Total phenols in white grapes.

• Grape and wine relationship not well established

for either because of processing effects.

• Aroma compounds in grape difficult to measure.

• Methodology(s) for measurement tedious and not

ready for production scale.
BUTYL ALCOHOL AND ACETONE
• All the acetone produced in the United
States was made by the dry distillation
of calcium acetate from pyroligneous acid.
• It has been discovered that the butyl-alcohol
producing bacteria in their life cycle synthesize vitamins.
• Riboflavin (Vitamin B) and other Vitamin B complex.
Uses and Economics
• Estimated that 40% of the butyl alcohol
and 4% of the acetone is produced
by fermentation.
• 70% of n-butyl alcohol enters directly into
lacquer solvents.
• Percentage breakdown of the end use of acetone is as follows:
cellulose acetate, 50; chemicals,15;
acetylene (solvent), 5; paint, varnish, and lacquer, 12;
drugs, 5; miscellaneous, 15.
Manufacturing Procedure
• Separating the corn oil, germ, and husks
by mixing with hot water and cooking.
• The cooking disperses starch into a so-called
soluble and sterilizes it so that the
microorganisms are killed.
• Complete sterilization
Manufacturing Procedure
• Fermentation with exact selection and cultivation of
selected microorganisms
• Respective desired bacteria is cultured
• Inoculate the sterile mash in increasing quantities
• Liberation of the hydrogen and carbon dioxide
• Fractionation
• Condensation
VINEGAR AND ACETIC ACID
What is Acetic Acid?
• Acetic acid or ethanoic acid
• Main constituent of Vinegar
• An antibiotic that treats infections caused by
bacteria or fungus
• Acetobacter which catalyse the oxidation of ethanol
to ethanoic acid.
What is Vinegar?
• Oxidation of alcohol to dilute acetic is
another ancient procedure, furnishing vinegar.
• Vinegar is a flavored acetic acid solution
• Fermented from wine, cider, malt, or dilute alcohol.
• If a pure dilute alcohol is fermented,
pure dilute acetic acid results.
• The yield is from 80 to 90% of theory.
Acetic Acid- a two step process
• Heating ethanol with an oxidizing agent such
as potassium dichromate solution
• Then acidified with sulphuric acid.
Uses and Economics
• Making cellulose acetate (for traditional photographic films,
as well as laminated coatings, etc.)
• Monomer used to make polyvinyl acetate a
wood glue.
• Employed to make ethyl acetate and
other esters.
CITRIC ACID
What is Citric Acid?
• Citric acid is one of our widely
employed organic acids
• Its major use is as an acidulant in
carbonated beverages, jams, jellies, and other foodstuffs.
• Another large outlet is in the medicinal
field, including the manufacture of citrates and
effervescent salts.
What is Citric Acid?
• Relatively small, include citric acid as a
sequestering agent and acetyl tributyl citrate,
a vinyl resin plasticizer
• Citric acid is manufactured by aerobic fermentation
of crude sugar by a special strain
of Aspergillus niger
• Over-all reaction

• The fermentation changes sugar, a straight-chain

into a branched chain
Tray Process for Citric Acid
• Air is circulated for 9- 12 days in
a shallow pure-aluminum trays with
sugar solution.
• Trays are placed in closed cabinet with
facilities for sterilization, ventilation, and
temperature control
• Submerged Fermentation
Tray Process for Citric Acid
Submerged process:
• Medium is prepared from decationized molasses feedstock,
decationized well water, and the nutrients
• Addition of morpholine to the medium
• Fermentation is carried out by a special
strain of A. niger
Tray Process for Citric Acid
Submerged process:
• Citric acid is recovered by precipitation
• Filtering or centrifuging and washing.
• The citric acid is liberated from the
salt by sulfuric acid
• Crystallized from the filtered, concentrated liquor.
LACTIC ACID
What is Lactic Acid?
• Lactic Acid is one of the oldest
known organic acid.
• The primary acid constituent of sour milk.
• Manufactured by the controlled fermentation of the hexose
sugars from molasses, corn, or milk.
• Lactates have been made by synthetic methods
from acetaldehyde.
What is Lactic Acid?
• Since 1930, lactic acid has been produced
commercially from the milk by-product whey.
• 12 billion pounds of whey are produced annually
from cheese or casein.
• Less than 2.5 billion pounds is employed in
food, feeds, or the production of lactose,
the rest being wasted or fed to animals.
Lactic Acid
• Lactic acid can be produced by the
fermentation of bacterial or fungal strains
• Lactobacillus sp. (bacteria) and Rhizopus sp. (fungi) are the
commonly used strains.
• This eliminates most contamination problems.
• There has been increasing interest in fungal
fermentation with Rhizopus oryzae for lactic acid
production.
Lactic Acid
• After fermentation, yields of 85% lactic acid
based on the weight of the fermentable
sugar are normal.
• Calcium lactate is decomposed by sulfuric acid
to regenerate the lactic acid
• The finer grades are made from calcium
lactate that has been crystallized at least once.
Uses and Economics
• Large amount of Lactic Acid is consumed annually
• The remaining percent is converted into plastics
solvents, and other chemical products.
Streptomycin and Dihydrostreptomycin
• The commercial method of producing these compounds
is also an aerobic submerged fermentation
• The medium must be rich in protein,
and such sources as meat extracts, fish
meal, and soybean are commonly used.
• This antibiotic is recovered from the filtered broth
by an ion-exchange process.
Chloromycetin
• Unique among Antibiotics
• Produced by both submerged- aerobic fermentation and
a complicated synthetic process.
• In 1950 it is believed that only
20% or less was produced by fermentation
Bacitracin
• Produce from Bacillus subtilis and related bacteria
of the gram-positive spore-forming rod type
• Commercially most important.
• Stimulates the growth and reduces the mortality
of poultry and swine.
• Produced by a submerged-fermentation process of
mash containing soybean meal, then by filtration
and solvent extraction purification.
Aureomycin and Terramycin
• Known that they involve aerobic submerged-fermentation
processes.
• These are likewise valuable in animal-feed
supplements.