Industrial fermentation

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Industrial fermentation is a biotechnological process which uses microorganisms (genetically modified or not), in particular bacteria, yeasts, fungi or algae, to make useful products. The cells are real "cell factories" for the industrial conversion of renewable feedstocks to bulk chemicals, fine chemicals, platform chemicals, pharmaceutical ingredients, bio-fuels, bio-plastics ... It is a multidisciplinary technology and includes the integrated application of disciplines such as biochemistry, microbiology, molecular genetics and process technology to develop useful processes and products.

Feedstock

Origin and composition

First generation feedstocks, such as: corn, wheat, sugarcane, potato, sugar beet, rice and plant oil.

Second generation feedstocks, such as: lignocellulosic biomass or woody crops, agricultural residues or waste.

Third generation feedstocks: gas fermentation

Process and technologies

Microorganisms

In practice, well-known, productive and harmless production organisms are used that, equipped with the new genetic information, will produce the desired products in high yield and efficiency. These are the so-called GRAS organisms (Generally Regarded As Safe) and belong to the genera Bacillus, Aspergillus, Penicillium, Saccharomyces, etc. A major advantage is that these genetically modified microorganisms do their work under controlled conditions in a fermenter or bio-reactor, carefully contained and separated from the outside world (contained environment). They cannot escape from the factory so that ecological problems or concerns regarding the release of genetically modified organisms in the environment are avoided.

Fermentation mode

Industrial fermentations may be carried out batchwise, as fed-batch operations, or as continuous cultures. Batch and fed-batch operations are quite common, continuous fermentations being relatively rare

Scale-up of industrial fermentations

Typically, a pure starter culture (or seed), maintained under carefully controlled conditions, is used to inoculate sterile petri dishes or liquid medium in the shake flasks. After sufficient growth, the preculture is used to inoculate the seed fermenter. Because industrial fermentations tend to be large (typically 1–250 m³), the inoculum is built up through several successively larger stages, to 5–10% of the working volume of the production fermenter. However, scale-up of a fermentation process is not straightforward as an increase in fermenter size affects the various process parameters in different ways. Therefore, ample expertise is required to find a compromise between all process parameters.

Types of fermentation

1. Alcoholic fermentation
2. Lactic acid fermentation
3. Propionic acid fermentation
4. Butyric acid — butanol Fermentation
5. Mixed acid fermentation.

Products

Biomass

Single cell protein (SCP)

Bio-products

Organic acids

Lactic acid can further be converted into polylactic acid (PLA), a bioplastic.

Citric acid a feed additive

Vitamins

Vitamin C

Vitamin-B12

Antibiotics

Amino-acids

Several products possible, examples

• Speciality carbohydrates,
• Industrial enzymes
• surfactants
• organic acids
• solvents
• flavours and fragrances
• biostimulants
• polymers
• protein concentrates
• nutraceuticals
• advanced fuels

Post-treatment

The first step in the post-treatment of fermentation broths cultures, also known as downstream processing (DSP), to remove the cells from the medium. This is typically performed by a solid-liquid separation technology, such, as centrifugation or membrane filtration. Each fraction can then undergo further processing, depending on whether the product is the biomass itself or an intra- or extracellular product. While intracellular products require cell disruption to release the products, extracellular products are solubilized in the depleted fermentation medium. Cell disruption techniques can be divided into mechanical methods (f.e. homogenisation, grinding, sonication, microwave treatment, steam explosion) and non-mechanical methods (f.e. osmotic or temperature shock, enzymatic destruction). To further purify and concentrate the products several methods can be used including chromatography, solvent extraction, crystallization, distillation, drying etc.

Technology providers

Company 1

Industrial fermentation provider

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Technology and process details
Technology name:		Technology category:	Conversion (Biochemical processes and technologies)
TRL:		Capacity:	kg·h-1
Aeration:		Agitator:
Biosafety level:		Controlled parameters:
Microorganism:		Reactor material:
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Feedstock and product details
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Bio Base Europe Pilot Plant (BBEPP)

Bio Base Europe Pilot Plant (BBEPP) is a flexible and diversified pilot plant for the development and scale up of new, bio-based and sustainable processes. It is capable of development of new bioprocesses, optimization of existing processes and scale up of a broad variety of bio-based processes up to an industrial level (from 5L to 50m3 scale, depending on the process). It can perform the entire value chain, from the green resources up to the final product. BBEPP intends to close the gap in the innovation chain of the bio-based economy, bridging science and industrial production. It is located in Ghent, Belgium.

The activities of BBEPP can be categorized in:

• Development of bio-based and sustainable processes (TRL 2-4)

• Scale up (TRL 5-6)

• Pilot and demo production to allow market introduction (TRL 7-8)

BBEPP has more than 10 years of experience in optimizing, scaling and transferring your fermentation protocol from the lab to commercial production. We count on an entire team of well-trained and highly motivated fermentation experts both with academic and industrial backgrounds to take your process to the next level!

Open access pilot and demo facility providers

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