Bioconversion of starch
- 2. BIOCONVERSION The conversion of organic materials suchas plant and animal waste into usable products or energysources bybiological processes agents. Source: Hermitica Bioconversion
- 3. WHY BIOCONVERSION? Source: Hermitica Bioconversion
- 4. FACTSAND FIGURES • According to FAO, nearly 1.3 billion tones of foods including fresh vegetables, 66 fruits, meat, bakery and dairy products are lost along the food supply chain. • The annual amount of urban FW in 70 Asian countries could rise from 278 to 416 million tones from 2005 to 2025. • FW is traditionally incinerated with other combustible municipal wastes for generation of heat or energy. • It should be realized that FW indeed contains high level of moisture and this may lead to the production of dioxins during its combustion. • In addition, incineration of FW can potentially cause air pollution and loss of chemical values of FW. • Total sugar and protein contents in FW are in the range of 35.5–69% and 3.9–21.9%, respectively. • FW has been used as the sole microbial feedstock for the development of various kinds of value-added bioproducts, including methane, hydrogen, ethanol, enzymes, organic acid, biopolymers and bio- plastics Source: Esra Uckun Kiran et al, 2014
- 5. BIOPRODUCTS FROM STARCHWASTE LACTIC ACID PROTEIN SYNTHESIS AMYLOLYTIC ENZYMES ETHANOL PRODUCTION METHANE PRODUCTION HYDROGEN PRODUCTION XYLITOL ASTAXANTHIN
- 6. CONVERSION OF WASTE POTATO STARCH INTO LACTIC ACID FERMENTATION AND RECOVERY PROCESS FOR LACTIC ACID PRODUCTION(Tsai et al) United States Patent. • To provide an efficient process for producing lactic acid of sufficient purity to make a degradable plastic of lactide polymers and copolymers from a renewable biomass material in a sufficiently short process time to render the entire method economically viable. • To provide a process for converting industrial food waste to glucose and lactic acid by the use of both enzyme and microbiological action, wherein the processing time to produce over 90% glucose is reduced to less than 10 hours and the subsequent process time is less than about 48 hours to produce lactic acid from the glucose.
- 7. POTATO WASTE HOMOGENISATION STARCH SEPERATION UNIT STARCH SLURRY LIQUIFICATION/ SACCHARIFICATION LIQUIFIED STARCH FERMENTATION CELL SEPERATION- CELL MASS/CELL FREE BROTH CRUDE LACTIC ACID VACUUM EVAPOURATION CONCENTRATED LACTIC ACID PURIFICATION- EXTRACTION PURIFIED LACTIC ACID
- 8. 1. A flow diagram of the preferred process of converting the potato waste to high purity lactic acid. 2. The potato waste is fed to the homogenizer which can be a hammer mill or Rietz mill, to produce a potato waste homogenate. 3. Separation of the potato starch from other components of the homogenate, is performed in the optional starch separation unit which includes a shaker screening and a settling tank or a centrifugal separator. 4. The starch slurry is pumped to the liquefaction unit to produce a liquefied starch. At pH 5 alpha-amylase is added with stabilising material calcium chloride. 5. After mixing above components the material is heated at 90-130ºC at 15psi for 15min.This process reduces microbial activity. 6. The material is then cooled at 50-70ºc at pH below 6.5. 7. After the temperature is lowered, glucoamylase is added in the mixture .The incubation time is 4-8hrs for conversion of 90% glucose.
- 9. 8. The potato hydrolysate is passed through filtration device wherein the solids are separated from glucose- containing filtrate. 9. The filtrate containing glucose is added with nutrients to facilitate fermentation of glucose to lactic acid. 10. The fermenter is fed with microbial inoculum (mixed culture of L.delbrueckii subsp. lactis, L. casei, L. helveticus) and nutrients (trypticase peptone, yeast extract, tryptose and sodium acetate) 11. During fermentation, a sodium hydroxide solution is added to the fermenter for pH control. 12. The fermentation broth containing cell mass and sodium lactate, is processed by a cell separator which can be a centrifuge to produce a cell-free broth containing sodium lactate solution and a cell mass concentrate. 13. The cell mass concentrate is recycled to the fermenter and part of it goes to waste.
- 10. 14. The cell-free broth is fed to the electrodialysis to generate a sodium hydroxide solution (which is recycled for fermentation pH control), and a crude lactic acid which is further concentrated in a vacuum evaporator at 60°—70° C. 15. The concentrated crude lactic acid produced from the vacuum evaporator is further processed in the purification process to produce a purified lactic acid. 16. The purification process is done by extraction. The crude lactic acid with an extractant (such as a tertiary amine in a water- immiscible organic solvent) and back-extracting the lactic acid from the extractant using a concentrated alkali solution (such as sodium hydroxide) resulting in a lactate salt (e.g., sodium lactate). 17. The lactate solution can then be processed by electrodialysis to recover the alkali solution and a purified lactic acid. 18. The purified lactic acid is fed into the polishing unit, which may include treatment by ion exchange resins and activated carbon. 19. The polished lactic acid is further concentrated in the final evaporation to generate the final product, a high purity lactic acid.
- 11. APPLICATION OF PLA 1. Bags for salads.The fast food chain such as McDonald’s is using PLA cups for packaging salads. 2. Coca-Cola is another company that is looking to implement PLA into its operation.They are currently developing a PET “Plant Bottle” that will contain 25% PLA (Kalkowski). 3. Some of the most common uses include plastic films, bottles, and biodegradable medical devices (e.g. screws, pins, rods, and plates that are expected to biodegrade within 6-12 months. 4. PLA constricts under heat and is thereby suitable for use as a shrink wrap material. SOURCE: creativemechanism.com; PLA:A Critical Analysis
- 12. FUNGAL BIOMASS PROTEIN PRODUCTION FROM STARCH PROCESSING WASTEWATER • Bioconversion of wastes is a natural way of recovering useful resources. • Biotechnology can facilitate this natural recycling process. • Biotechnological treatment of food processing wastes, which exist in huge quantities, can produce a valuable end-product, e.g. microbial biomass protein (MBP). • The manufacturing of starch products from wheat, corn and potato involves significant usage of water. • This voluminous water usage results in the generation of substantial quantities of wastewater. The vast quantities of starch processing wastewater (SPW) have higher biochemical oxygen demand (BOD), levels than town sewage, are highly polluting, and can impose heavy loads on the environment or be expensive in terms of sewer disposal. • The SPW, with a relatively high percentage of carbohydrates, cellulose, protein and plant nutrients, represents an important energy-rich resource. Source: Bo Jin et al, 2002
- 13. STARCH HYDROLYSIS • Microfungi of A. oryzae and R. oligosporus possess a high amylolytic enzyme activity. • The amylase enzymes are preferred for use in fermentation for human or animal consumption, and have been extensively used in fermentation industries to produce traditional beverages and fermented foods. PROTEIN SYNTHESIS • The fungal biomass contained more than 45% protein and appreciable quantities of amino acids. • Safe for human and animal consumption. • Microfungi have a number of properties which make them important both scientifically and industrially. • They play an important role in the food industries, are known to have a wide range of enzymes, and are capable of metabolising complex mixtures of organic compounds occurring in most wastes. • Cultivating microfungi to yield biomass protein is particularly attractive because: 1. Microfungal cells contain reasonably high levels of protein; 2. Microfungi contain a lower amount of nucleic acid than yeasts and bacteria. 3. Food produced from fungi is traditionally eaten in many parts of the world. • Fungi can be grown using almost any waste products that contain carbohydrates, such as confectionery and distillery waste, vegetable waste and wood processing effluents. •The enzyme-producing fungal species of Aspergillus oryzae and Rhizopus oligosporus were used for starch hydrolysis and protein synthesis. Source: Bo Jin et al, 2002
- 15. ETHANOL PRODUCTION • Without thermal sterilization, acidic condition is needed to prevent microbial contamination and putrefaction PRE- TREATMENT • a-amylase, b-amylase, glucoamylase and pullulanase (catalyze the hydrolysis of a-1,6-glucosidic linkages) is added • Small fermentable sugars (e.g. maltose, amylose, glucose, and fructose) can be produced SACCHARIFI- CATION • The fed-batch culture has been commonly employed for the production of high concentration reducing sugars which can be further fermented to ethanol (Compared to batch culture, fermentation were both improved significantly using fed-batch configuration, e.g. the glucose bioconversion yield reached 92% of its theoretical value). PROCESS CONFIGURA- TION Source: Esra Uckun Kiran et al, 2014
- 16. HYDROGEN PRODUCTION Hydrogen (H2) is used as compressed gas and has a high energy 225 yield (142.35 kJ/g). FW rich in carbohydrate is suitable for H2 production. • Hydrogen production potential of carbohydrate-based waste was reported to be 20 times higher than that of fat-based and protein- based waste. • H2 yield was found to increase at lower C/N ratio. SUBSTRATE COMPOSI- TION • FW itself can be a source of H2-producing microflora. Lactic acid bacteria are the most abundant species in untreated FW. • Heat treatment is effective for suppressing lactate production and increasing H2/butyrate production. PRE- TREATMENT • The optimum pH for H2 production from organic waste ranged from 4.5 to 6.5.The accumulation of fermentation products, i.e. CO2, increases the acidity and then inhibits the microbial growth. • Such fermentation products can be removed by simple gas sparging and addition of alkaline. PROCESS CONFIGURA TION Source: Esra Uckun Kiran et al, 2014
- 17. METHANE PRODUCTION The production of biogas, particularly methane via anaerobic processes is an acceptable solution for waste management because of its low cost, low production of residual waste and its utilization as a renewable energy source. • Single-stage anaerobic digestion process has been employed for municipal solid waste treatment. • As all of the reactions take place in a single reactor, the system encounters less frequent technical failures and has a smaller investment cost. • The anaerobic digestion can be wet or dry. Compared to wet anaerobic digestion, dry anaerobic digestion provides lower methane production Single- stage anaerobic digestion • Two-stage anaerobic digestion has often been used for producing both hydrogen and methane in two separate reactors. • In the first stage, fast-growing acidogens and hydrogen producing m/o are enriched for the production of hydrogen and volatile fatty acid (VFAs). • In the second stage, slow-growing acetogens and methanogens are built-up, whereVFAs are converted to methane and carbon dioxide. Two- stages anaerobic digestion Source: Esra Uckun Kiran et al, 2014
- 18. Xylitol is a sugar alcohol derivative of xylose, valuable as a sugar substitute. Xylitol is equivalent to sucrose in sweetness, but unlike sucrose it is anticariogenic and metabolized by an insulin-independent pathway. Xylitol is used to make mint, candies, toothpaste. Conventionally produced by a chemical process from birch wood chips and is relatively expensive at about $7 kg. It has been suggested that a bioconversion process could offer a more economical alternative. Numerous yeasts convert xylose to xylitol,particularlyincluding species of Pichia and Candida. Astaxanthin is the carotenoid pigment that gives salmon their characteristic color. The pigment is important for consumer acceptance and also may have health benefits. For farm-raised salmon, astaxanthin is an expensive feed supplement. The red yeast Phaffia rhodozyma is a natural source of astaxanthin that has been commercially developed as an aquaculture feed supplement. Five naturally occurring strains of P. rhodozyma have been tested for growth and carotenoid production on a standard laboratorymedium and on media containing only clarified corn residues in distilled water. Source:Timothy D et al,2002
- 19. BIBLIOGRAPHY• FERMENTATIONAND RECOVERY PROCESS FOR LACTIC ACID PRODUCTION(Tsai et al) United States Patent. • https://www.creativemechanisms.com/blog/learn-about-polylactic-acid-pla- prototypes • PLA: A Critical AnalysisCasey Kingsland Mohawk College of AppliedArts and Technology • www.hermiticabioconversions.com • Bioconversion of food waste to energy:A review, 2014.Esra Uckun Kiran, Antoine P. Trzcinski,Wun Jern Ng,Yu Liu. Advanced Environmental BiotechnologyCentre, Nanyang Environment &Water Research Institute. • Bioconversions of maize residues to value-added coproducts using yeast-like fungi, 2002.Timothy D. Leathers Fermentation Biotechnology Research Unit, National Center for Agricultural Utilization Research, Agricultural Research Service, United States • A comprehensive pilot plant system for fungal biomass protein production and wastewater reclamation (2002) Bo Jin, X.Q.Yana, Q.Yu, J.H. van Leeuwen