Rapid fermentation of beer using an immobilized yeast multistage bioreactor system

Encapsulation of brewers yeast in chitosan coated carrageenan microspheres by emulsification/thermal gelation

Brewers yeast was encapsulated in kappa-carrageenan microspheres using an emulsification-thermal gelation approach. Due to heat sensitivity of the yeast at temperatures in excess of 36 degrees C, mixtures of low and high gelation temperature carrageenans were tested to obtain a blend yielding a gelation temperature under 40 degrees C. A 20:80 dispersion of 2% carrageenan sol containing cells, in warm canola oil, produced microspheres upon cooling, with a mean diameter of 450 microm and narrow size dispersion (span of 1.2). Application of a chitosan membrane coat to minimize cell release, increased the mean microsphere diameter to 700 microm, due to the coat thickness and swelling of the microspheres. This diameter was designed so as to minimize mass transfer limitations. Batch fermentations were carried out in a 3 L reactor on a commercial wort medium. Cell loading was 10(7) cells mL(-1) microspheres, and cell "burst" release was observed upon inoculation into fresh medium, whether microspheres were coated or not. The kinetics of intra- and extracapsular cell growth were determined. Increased concentrations of extracapsular free cells could be accounted for by growth in the wort medium, and by ongoing release from the gel microspheres, whether coated or not. Cell release from chitosan-coated carrageenan microspheres was less than that from uncoated microspheres, likely due to retention by the membrane coat. Growth kinetics and alpha-amino nitrogen consumption of encapsulated yeast were higher than that of free cells, and differences in alcohol and ester profiles were also observed, likely due to modified metabolism of the encapsulated yeast.