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Bioprocess Engineering
EPT 112/3: Introduction to Engineering 1
BFT112 INTRODUCTION TO ENGINEERING
DR. RITA MOHD SAID
Outlines
EPT 112/3: Introduction to Engineering 2Creadit to: Nor Helya Iman Bt. Kamaludin
1. Introduction to biotechnology, bioprocess &bioprocess Engineering
2. Bioprocess Industries3. Product and Services by Biological Processes4. Fermentation Process5. The importance areas of Bioprocess
Engineering
Introduction to Biotechnology & Bioprocess Engineering
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• Art and science of converting reactants(substrate) into useful products by the action ofmicroorganisms or enzymes.
Biotechnology
• Any process in which microbes or living organismsplay a vital role in getting transformation of thefeed into useful product.
Bioprocess
• Usage of engineering principles or terms toanalysis of and development and also design ofmethods using biological catalysts like enzymes,living cells, and genetically engineered cells
Bioprocess engineering
Biotechnology & Bioprocess
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Biotechnology Bioprocess
A study about biologicalsystems or living organismsto make or modify productsor processes for specificuse, such as in agriculture,food production, andmedicine.
A branch ofchemical/processengineering, which dealswith the design anddevelopment of equipmentand processes that usebiological component suchas enzyme, bacteria, oryeast
biotechnology researchersmay develop a new strainof yeast for fermentationprocess
bioprocess engineers willdesign equipment andprocess condition to carryout the fermentationprocess in industrial scale
Bioprocess engineering/Biochemical engineering
The efficient utilization of physical, chemical and biologicalprocesses to convert raw materials into useful products, atminimal cost, with minimal energy consumption, and withminimal impact on the environment.
Involve the process for developing useful products by takingadvantage of natural biological activities.
Classical example include making alcoholic beverages – theyeast cells and nutrients (cereal grains) formed afermentation system in which the organisms consumed thenutrients for the growth and produced by-products (alcohol).
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Bioprocessing•Because bioprocesses use living material, they offer several advantages over conventional chemical methods of production:
They usually require lower temperature, pressure, andpH.
They can use renewable resources as raw materials;and greater quantities can be produced with lessenergy consumption.
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Bioprocessing
• In bioprocesses, enzymes are used to catalyze the biochemicalreactions by whole microorganisms or their cellularcomponents.
• The biological catalyst causes the reactions to occur, but is notitself changed.
• After a series of such reactions (which take place in largevessels called fermentors or fermentation tanks), the initial rawmaterials are chemically changed to form the desired endproduct.
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Biologist and engineers differ in their approach to research
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Biologist Engineers
• Have incompletebackgrounds inmathematics theories
• Posses a very goodbackground in the physicaland mathematical sciences
• Have very strong skills withrespect to laboratory toolsand interpretation oflaboratory data fromcomplex systems
• Typically unfamiliar with theexperimental techniquesand strategies used by lifescientists
Bioprocess Industries
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Major area
Pharma-ceuticals
Environmental management
AgricultureFood
Chemicals/Energy
Product and Services by Biological Processes
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Industry Product and Service
Chemicals/Energy Ethanol, acetone, butanol Organic acids (acetic, propionic and citric acids) Enzymes Perfumeries PolymersMethane (biogas)
Pharmaceuticals AntibioticsMonoclonal antibodies Steroids Vaccines
Environmental-management control or remediate toxic wasteWaste treatment
Food Diary products (cheese, yoghurts, etc.) Baker’s yeast Beverages (beer, wine) Vitamin B
Agriculture Animal feedsVaccinesMicrobial pesticides
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Product and Services by Biological Processes
Fermentation Process
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What is fermentation processes??
• is a metabolic process in which an organism converts acarbohydrate, such as a sugar, into an alcohol or an acid.
• For example, yeast performs fermentation to obtain energyby converting sugar into alcohol. Bacteriaperform fermentation, converting carbohydrates into lacticacid
Sources of fermentation process
Microorganism involved
• Yeast (saccharomyces cerevisiae)
• Fungi (aspergillus niger, rhizopus oryzae,etc)
• Bacteria (pseudomonas sp., bacillus subtilis, streptomycesolivaceus, etc)
Molasses, corn syrup, grain, fruit extract, agricultural wastes , etc.
Video: Fermentation Process
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Industrial Fermentation
Definition:
The growth of microorganisms or cells in a large scale for producing
specific products
Equipment used:
Bioreactor
Size: up to 100 m3
Parameter to be controlled: aeration, pH
and temperature
Microorganisms and Products:
Yeast: bread, cheese, yoghurt, wine
Fungi: lactic acid (rhizopusoryzae), gluconic acid
(aspergillus niger)
Bacteria: Insulin (recombinant E.coli),
antibiotics (streptomyceserythreus)
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FERMENTATION APPLICATION AND ITS
PRODUCT
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Products of Fermentation
Production of Lactic Acid
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Overview of Lactic Acid
• Lactic acid, also known as milk acid, is a chemical compound thatplays a role in various biochemical processes.
• Lactic acid is a carboxylic acid with the chemical formula (C3H6O3).
• It is the acid ingredient of sour dairy products, fermented fruits &vegetables and sausages.
• Many bacterial species produce lactic acid: Lactobacillus,Bifidobacterium, Streptococcus, Pediococcus and Leuconostoc.
• Lactic acid found in animals and humans has many functions, themost important is to the supply of energy in muscle tissue.
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Lactic Acid Manufacture
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Raw materials
• Carbohydrates
• Exp: corn, potato, molasses, whey
Exp: Production of lactic acid from whey
• Whey: waste product in manufacture of dairy products such as cheese
• Disposal of untreated waste may create environmental problems
• Whey can be converted from being a waste product to something more desirable.
Whey contain lactose, nitrogenous substances, vitamins and salts
Fermentation of lactose
Bacteria (Lactobacillus bulgaricus) utilise lactose and growth rapidly on whey
Capable of converting lactose to single end-product (lactic acid)
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Application of Lactic Acid Fermentation
• Lactic acid fermentation is a biological process by which sugars suchas glucose, fructose, and sucrose, are converted into cellular energyand the metabolic byproduct lactate.
• Lactic acid fermentation is used in many areas of the world toproduce foods that cannot be produced through other methods.
• Two of the most common applications of lactic acid fermentationare in the production of:
yogurt sauerkraut (pickled cabbage)
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Yogurt Production
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• Yogurt is a semi-solid fermented milk product that originated centuries ago and has evolved from many traditional Eastern European (e.g., Turkish and Bulgarian) products.
What is yogurt???
• Animal’s milk: cow’s milk, etc.
• Other dairy products: concentrated skim milk, nonfat dry milk, whey, lactose.
• Sweeteners: glucose or sucrose, high-intensity sweeteners (e.g. aspartame)
• Stabilizers: gelatin, carboxymethyl cellulose, locust bean gum, guar, alginates, carrageenans, whey protein concentrate
• Flavours
• Fruit Preparations: including natural and artificial flavouring, colour
Ingredients
• Streptococcus thermophilus (ST)
• Lactobacillus delbrueckii subsp. bulgaricus (LB)
Starter Culture
Yogurt Manufacture
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The milk is clarified and separated into cream and skim milk, then standardized with other dairy ingredients to achieve the desired fat and milk solids-not-fat content.
The various ingredients are then blended together in a mix tank equipped with a powder funnel and an agitation system.
The mixture is then pasteurized using a continuous plate heat exchanger for 30 min at 85° C or 10 min at 95° C.
The mix is then homogenized using high pressures of 2000-2500 psi.
Besides thoroughly mixing the stabilizers and other ingredients, homogenization also prevents creaming and wheying off during incubation and storage. Stability, consistency and body are enhanced by homogenization.
Once the homogenized mix has cooled to an optimum growth temperature, the yogurt starter culture is added.
A ratio of 1:1, ST to LB, inoculation is added to the jacketed fermentation tank.
A temperature of 43°C is maintained for 2-2.5 h under quiescent (no agitation) conditions.
The coagulated product is cooled to 5-22°C, depending on the product. Fruit and flavour may be incorporated at this time, then packaged.
The product is now cooled and stored at refrigeration temperatures (5° C) to slow down the physical, chemical and microbiological degradation.
Video: Yogurt Production
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Production of Vinegar
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Overview of Vinegar
• Vinegar is a liquid substance consisting mainly of acetic acid and water; the acetic acid being produced through the fermentation of ethanol by acetic acid bacteria.
• In food preparation procedures, it is a multi-purpose product as an ingredient and condiment.
• Outside of cooking, vinegar has medicinal, household cleaning, and agricultural applications.
• Vinegar is made from the oxidation of ethanol in an alcohol-containing liquid, such as wine, fermented fruit juice, or beer.
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Types of vinegar:
depends on the kind of material used in the alcoholic fermentation
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vinegar
Cider vinegar
Apple vinegar
Vinegar Manufacture
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Raw materials
• Fruits
• Exp: grapes, apples, raspberries, cherries, lemons, etc.
Microorganism
• Acetobacter
• Gluconobacter
Two important steps in production of vinegar:
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Acetic acid (vinegar) production
Acetobacter and Gluconobater oxidise ethanol in wine to acetic acid (vinegar)
Wine production
Sugar in fruits such as grapes are fermented by yeast to produce wines
Reaction involved:
C6H12O6 → 2CH3CH2OH + 2CO2
2CH3CH2OH + 2CO2 → 2CH3COOH + 2H2O
Zymomonas mobilis
Acetobacter sp.
Production of Penicillin
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Overview of Penicillin
• Penicillin is a group of antibiotics derived fromPenicillium fungi.
• They include penicillin G, procaine penicillin,benzathine penicillin, and penicillin V.
• Antibiotics are natural substances that inhibits thegrowth of or destroys microorganisms
• Penicillin antibiotics are historically significantbecause they are the first drugs that were effectiveagainst many previously serious diseases, such assyphilis, and infections caused by staphylococci andstreptococci.
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Penicillin Manufacture
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Raw materials
• Molasses, corn steep liquor; wasteproduct from sugar milling corn
Microorganism used for penicillin production
• Mould species: Penicillium chrysogenum
• Can produce 1000 times more penicillin than previous method; original culture.
Major steps in commercial penicillin production
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Preparation of inoculum
Preparation and sterilisation of medium
Inoculation of the medium in fermenter
Forced aeration with sterile air during incubation
Removal of mould mycelium after fermentation
Extraction and purification of the penicillin
Production of Enzyme
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Overview of enzymes
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What is enzymes??
• Proteins of higher molecular weight that act as catalysts
Function of enzymes
• To increase the reaction rates of chemical and biological processes
Characteristics of enzymes
~ specific
~ denatured by heat (at higher temperature)
~ extracted or precipitated by chemical solvents
such as ethanol
~ very effective biological catalysts
Industrial application of enzymes
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Enzyme Application
Trypsin Anti inflammatory agent
Lysozyme Anti bacterial agent
Streptokinase Anti inflammatory agent useful for dissoluting blood clots
Urokinase Prevention of blood clots
Aspuraginase Anti cancer agent
Penicillinase Treatment of allergies against penicillin
Papain Tenderization of meat
Pectinase Clarification of fruit juices and wine
Chymosin Cheese production
Urease Conversion of urea into carbon dioxide and ammonium in dialysis process
The importance areas of Bioprocess Engineering
• Agriculture industryProduction of agricultural chemicalsfor and plant diseases, growth-stimulating a yield, production ofbiological insecticide and efficienttreatment and management wastes.
• Food industryIncreasing bioprocess efficiencies forfermen natural food additives, foodenzymes as process separation andpurification of the products,treatment wastes from food-processing industry.
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• Renewable energy industry
Efficient use of renewable biomass resourcesof liquid fuel and chemical feedstocks.
• Chemical and pharmaceutical industry
Use of plant-cell culture systems to producesecondary metabolites or chemical substances
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EXCERCISE1. Differentiate between bioprocess, bioprocess engineering and
biotechnology. (6 marks)
2. List FIVE (5) major areas involved in bioprocess industry and giveTWO (2) products produced from each industry. (15 marks)
3. What is meant by lactic acid fermentation? Give TWO (2)products mainly produced through this process. (5 marks)
4. List FOUR (4) areas the importance of Bioprocess Engineering.(4 marks)
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