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BAKER’S YEAST PRODUCTION AN OVERVIEW A SCHEMATIC FLOW DIAGRAM FOR THE PRODUCTION OF BAKER’S YEAST Chemicals Beet PC Culture Ammonia F1 Pasteur flask Cane F2 H3PO4 Aeration Minerals De Vitamins former Mixer Clarifier Air blower Wort storage F3 Cooler Wash & Storage F4 Separator For compressed Filter press Mixer & extruder Packaging Storage 3-5C Consumer For ADY Filter press Extruder Dryer Packaging Bulk Cool storage CELL DIVISION BY BUDDING BUD INNITIATION DAUGHTER CELL (NUCLEUS) DNA BUD SCAR MOTHER CELL DNA DUPLICATION BUD ENLARGEMENT, NUCLEAR MIGRATION MOTHER CELL BASIC REQUIREMENTS FOR CELL DIVISION ‡ Carbon matrix to build the structure (glucose or ethanol) ‡ Nutrients to produce bio-molecules (O2, P, N, micro nutrients, Trace elements, etc) ‡ Energy source to drive the biological systems (Glucose or Ethanol) PREREQUISITS FOR BUDDING OR CELL DIVISION Bud scar OXYGEN CARBON SOURCE PHOSPHATE SOURCE Mother cell NITROGEN SOURCE Daughter cell MICRO NUTRIENTS CHROMOSOME DOUBLING BEFORE CELL DIVISION POWER BEHIND LIFE LIFE NEEDS ENERGY TO CARRY OUT ITS TASKS ATP - LIFE’S BATTERY IT’S THE ENERGY CURRENCY MOLECULE OF CELL GLUCOSE OR ETHANOL AT HIGH OXYGEN TENSION PROVIDES THE NECESSARY ATP TO DRIVE ALL REACTIONS INCLUDING CELL DIVISION HOW YEAST BEHAVES UNDER AEROBIC VS ANAEROBIC CONDITIONS ANAEROBIC (No Oxygen): Alcoholic fermentations, Example: wine or beer fermentations AEROBIC (In the presence of Oxygen) Yeast propagation CRITICAL DIFFERENCE IN ATP GENERATION Alcohol production via anaerobic conditions utilize one pathway ATP produced by anaerobic pathway is low (2ATPs) Biomass production via aerobic conditions utilize another pathway ATP production via aerobic pathway is high (38ATP) METABOLIC FATE OF GLUCOSE UNDER ANAEROBIC VS AEROBIC CONDITIONS ANAEROBIC AEROBIC GLUCOSE Glycolysis 2ATP PYRUVATE At high O2 and/or low glucose AS WITH CELL PROPAGATION 36ATP Acetaldehyde ETHANOL At low O2 or high glucose AS IN A WINE FERMENTATION A decision point for carbon flow depending on oxygen tension and sugar in the medium METABOLIC FATE OF GLUCOSE AS DICTATED BY FEED RATE AND OXYGEN (AIR) GLUCOSE Glycolysis At high O2 and/or low glucose PYRUVATE Acetaldehyde ETHANOL TCA CYCLE At low O2 or high glucose BIOMASS PROPOSED PATHWAY FOR THE PRODUCTION OF BIOMASS FROM CORN SYRUP Glucose + O2 + N + P + Nutrients Biomass + CO2 + 38ATP GLUCOSE Feed-back control O2 Citrate Ethanol 3ATP CO2 TCA CYCLE CO2 Pyruvate - ketoglutarate 3ATP 8ATP Acetyl CoA 3ATP O2 CO2 Succinate 3ATP Oxaloacetate Fumarate Precursors BIOMASS Energy 3ATP ATP Malate Conditions that favor formation of volatiles during propagation of Torula Yeast Ethanol Acetaldehyde Low O2 Low Fe ADH Ethanol Acetaldehyde TCA Low O2 Ethyl acetate CYCLE Acetate Low O2 Low Fe CoA O2 Fe Acetyl CoA Acetate Excessive contaminants also contribute to higher level of volatiles thereby affecting yields Low Fe Ethyl acetate TYPICAL COMPOSITION OF CREAM OR COMPRESSED YEAST (ON SOLIDS BASIS) PROTEIN (N X 6.25) 52% CARBOHYDRATES 30% MINERALS 8% NUCLEIC ACID 5% LIPIDS 4% OTHERS 1% ACTIVE DRY YEAST CHARACTERISTICS OF ACTIVE DRY YEAST SPECIAL STRAINS WITH HIGH TREHALOSE ACCUMULATION USED TO WITHSTAND DRYING CONDITIONS MOISTURE CONTENT IN THE 3-7% RANGE YEAST LESS ACITVE THAN COMPRESSED ON EQUAL SOLIDS BASIS HENCE, HIGHER AMOUNTS NEEDED BETTER STORAGE STABILITY AT ROOM TEMPERATURE SIGNIFICANT SAVING ON TRANSPORTATION COSTS SPECIAL REHYDRATION PROCEDURES NEEDED EFFECT OF TREHALOSE DURING DRYING YEAST CELL 1 2 3 Proteins Shrunken Protein Lipids OUT DRYING DRYING Trehalose effect INSIDE Membrane Cell wall of compressed yeast Dry cell wall Leaky membrane A more stable membrane CRITICAL CONTROL POINTS IN THE PRODUCTION OF ACTIVE DRY YEAST LOWER % NITROGEN AIMED IN THE YEAST - GENERALLY IN THE 6.5 - 7% RANGE LESS PHOSPHERIC ACID TO COMPENSATE REDUCED AMMONIA END BUD INDEX TO BE LESS THAN 2% - CONTROL FEED AT END TO LIMIT BUDDING(MATURATION) EXTRUDE COMPRESSED YEAST TO 0.2 - 0.3 CM DRY IN TRAY DRYER (P & S DRYER) INSTANT ACTIVE DRY YEAST CHARACTERISTICS OF INSTANT ACTIVE DRY YEAST PRODUCTION PROCEDURE PARALLELS ADY PROCEDURE SPECIAL STRAINS USED FOR HIGHER ACTIVITY AND DRYABILITY LOW NITROGEN AIMED IN YEAST NO SPECIAL REHYDRATION PROCEDURE NECESSARY NOODLES MADE THINNER TO IMPROVE REHYDRATION GENERALLY VACUUM PACKED TO RETAIN STABILITY CRITICAL CONTROL POINTS IN THE PRODUCTION OF INSTANT ADY UP STREAM PROCESSING PARALLELS ADY PROCESS UP TO POINT OF CAKE PRODUCTION THINNER NOODLES TO INCREASE SURFACE AREA OF PELLETS EMULSIFIER TO IMPROVE EXTRUSION DRY BY A MORE GENTLE AIR LIFT DRYING PROCESS USE VACUUM PACK TO MAINTAIN STABILITY FOR LONGER PERIODS MECHANISM OF ACID TOLERANCE IN THE MICROBIAL WORLD H+ H+ pH gets lowered H+ ACID INTOLERANCE Example: Bacteria Proton Pump pH remains steady H+ ACID TOLERANCE Example: Yeast BACTERIA VS YEAST - MAJOR DIFFERENCES Yeast produces ethanol at low oxygen and biomass at high oxygen. Bacteria does not follow this rule. Hence, bacteria can proliferate more easily. Aerobic bacteria grow fast and anaerobic bacteria grow slower under high O2 tension. The opposite occurs at low O2 tension Growth rate of bacteria is 5 - 8 times faster than yeast Under conditions where yeast growth is suppressed, bacteria can gain dominance, instantaneously PROBABLE WAY THE CELLS INCREASE AFTER pH TREATMENT Yeast Generation time for yeast: 100 minutes Generation time for bacteria: 20 minutes 40 80 Bacteria 3 6 12 24 48 96 192 Time 0 20 40 60 80 100 120 (Minutes) PROBABLE MECHANISM IN THE INDUCTION OF ENZYMES TO UTILIZE A NEW SUBSTRATE EXAMPLE: A CHANGE FROM GLUCOSE TO ETHANOL ETHANOL Transcription ATP translation ATP Coiling ATP Enzyme DNA Gene Template Messenger RNA Polypeptide chain PYRUVATE [> 30 MINUTES] TCA cycle Tilak 11.4.04 BREAKDOWN OF SUGAR DURING WINE FERMENTATION Wine Fermentation C6H12O6 2[C2H5OH] + 2[CO2] + 57 kcal (2ATP) 180 92 88 C O O CH2OH H OH O H H OH OH H OH Glucose H H C C H H Carbon dioxide CO2; MW =44 OH Ethanol C2H5OH; MW=46 H O H (Corn Syrup) C6H12O6 ; MW=180 Water H2O; MW =18 BREAKDOWN OF SUGAR DURING YEAST PROPAGATION Baker’s propagation C6H12O6 + 6[O2] 180 BIOMASS + 6[H2O] + 6[CO2] + 686 kcal 192 108 (38ATP) 264 C O O CH2OH H OH O H H OH OH H OH Glucose H H C C H H Carbon dioxide CO2; MW =44 OH Ethanol C2H5OH; MW=46 H O H (Corn Syrup) C6H12O6 ; MW=180 Water H2O; MW =18