Process and cost modeling of lactic acid recovery from fermentation broths by membrane-based process

The outlooks and key challenges in renewable biomass feedstock utilization for value-added platform chemical via bioprocesses

The conversion of renewable biomass feedstock into value-added products via bioprocessing platforms has become attractive because of environmental and health concerns. Process performance and cost competitiveness are major factors in the bioprocess design to produce desirable products from biomass feedstock. Proper pretreatment allows delignification and hemicellulose removal from the liquid fraction, allowing cellulose to be readily hydrolyzed to monomeric sugars. Several industrial products are produced via sugar fermentation using either naturally isolated or genetically modified microbes. Microbial platforms play an important role in the synthesis of several products, including drop-in chemicals, as-in products, and novel compounds. The key elements in developing a fermentation platform are medium formulation, sterilization, and active cells for inoculation. Downstream bioproduct recovery may seem like a straightforward chemical process, but is more complex, wherein cost competitiveness versus recovery performance becomes a challenge. This review summarizes the prospects for utilizing renewable biomass for bioprocessing.

Modeling of lactic acid rejection from lactose in acidified cheese whey by nanofiltration

The continuously increasing demand of lactic acid opens a window for the integration of membrane technology in the dairy industry, improving the sustainability by avoiding the use of large amounts of chemicals and waste generation. Lactic acid recovery from fermentation broth without precipitation has been studied by numerous processes. In this work, a commercial membrane with high lactose rejection and a moderate lactic acid rejection, enabling a permselectivity up to 40%, is sought to perform the simultaneous removal of lactic acid and lactose separation from the acidified sweet whey from mozzarella cheese production in a single stage. The AFC30 membrane of the thin film composite nanofiltration (NF) type was selected because of its high negative charge, low isoelectric point, and divalent ion rejection, as well as a lactose rejection higher than 98% and a lactic acid rejection lower than 37%, at pH 3.5, to minimize the need of additional separation steps. The experimental lactic acid rejection was evaluated at varying feed concentration, pressure, temperature, and flow rate. As the dissociation degree of lactic acid is negligible in industrially simulated conditions, the performance of this NF membrane was validated by the irreversible thermodynamic Kedem-Katchalsky and Spiegler-Kedem models, with the best prediction in the latter case, with the parameter values: L_p = 3.24 ± 0.87 L × m^-2 × h^-1 × bar^-1 and = 15.06 ± 3.17 L × m^-2 × h^-1, and σ = 0.45 ± 0.03. The results obtained in this work open the way for the up-scaling of membrane technology on the valorization of dairy effluents by simplifying the operation process and the model prediction and the choice of the membrane.

Fouling of the Nanofiltration Membrane NF270 Used for Separation of Fermentation Broths: Impact of Feed Pretreatment Process

Recent findings regarding nanofiltration (NF) have led to indications that it can be successfully used for separation of various biological solutions. As a novelty, this paper is the first to investigate the impact of the feed pretreatment process on the NF membrane performance used for separation of 1,3-propanediol (1,3-PD) fermentation broths. For this purpose, prior to the NF process, the feed was purified by microfiltration (MF) and ultrafiltration (UF) processes. Subsequently, the long-term NF process was carried out with the use of a commercial, flat-sheet, thin-film, polyamide NF270 nanofiltration membrane. Thereinto, to determine the dominant fouling mechanism, Hermia’s model was used. With regards to the pretreatment processes performed, it has been determined that the MF membrane (0.14 µm) provided the reduction in the number of bacteria cells present in the permeate, while the UF membrane (450 Da) allowed obtaining the sterile permeate. Consequently, the NF permeate flux for the UF permeate was significantly higher. Analysis of the fouling mechanisms showed that during the separation of the MF permeate, formation of a cake layer on the NF membrane surface was dominant. In turn, with regards to the UF permeate, membrane blocking occurred in two separate phases involving standard blocking and then cake layer formation. Finally, a strategy of NF membrane cleaning with the use of sodium hydroxide (NaOH) solution has been proposed.

Viability of Listeria monocytogenes and Salmonella spp. on Slices of a German-Style Bologna Containing Blends of Organic Acid Salts During Storage at 4 or 12°C

Viability of cells of Listeria monocytogenes or Salmonella spp. was quantified on slices of a German-style bologna manufactured by a local butcher to contain no added antimicrobials or to include 0.9% or 1.3% of a blend of potassium acetate and sodium diacetate (K-Ace) or 2.5% of a blend of potassium lactate and sodium diacetate (K-Lac) as ingredients. After slicing (ca. 7.1 cm L by 6.7 cm W, ca. 0.5 cm thick, ca. 22.4 g each), a single slice of bologna was placed into a nylon-polyethylene bag and surface inoculated with 250 µL per side of a five-strain mixture of either cells of L. monocytogenes or Salmonella spp. to achieve an initial level of ca. 3.5-4.0 log CFU/slice. The packages were vacuum-sealed and then stored at 4 or 12°C for 90 and 30 days, respectively. Without antimicrobials added to the formulation, L. monocytogenes numbers increased by ca. 5.4 and 6.0 log CFU/slice at both 4 and 12°C during the entire 90- and 30-day storage period, respectively. Likewise, levels of Salmonella also increased by ca. 6.0 log CFU/slice at 12°C in the absence of added antimicrobials; however, levels of this pathogen decreased by ca. 1.7 log CFU/slice after 90 days at 4°C. With the inclusion of 0.9% or 1.3% K-Ace or 2.5% K-Lac in the bologna formulation, levels of L. monocytogenes decreased by ca. ≤0.7 log CFU/slice after 90 days at 4°C, whereas levels of Salmonella decreased by ca. 1.6-2.3 log CFU/slice. After 30 days at 12°C, levels of L. monocytogenes increased by ca. ≤3.4 log CFU/slice on product containing 0.9% K-Ace or 2.5% K-Lac but remained relatively unchanged on slices formulated with 1.3% K-Ace. For Salmonella, in the presence of 0.9% or 1.3% K-Ace or 2.5% K-Lac, pathogen levels decreased by ca. ≤0.7 log CFU/slice at 12°C after 30 days. Our data validate that the inclusion of K-Ace (0.9% or 1.3%) or K-Lac (2.5%) as ingredients is effective for controlling L. monocytogenes and Salmonella on slices of bologna during refrigerated storage.

Evaluation of Nanofiltration Membranes for Pure Lactic Acid Permeability

Lactic acid (LA) is an organic acid produced by fermentation or chemical synthesis. It plays a crucial role in the pharmaceutical, food and plastic industries. In the fermentation of, for example, grass silage, LA and different compounds are produced. To purify lactic acid, researchers have tried to investigate membrane technology to achieve a high yield of lactic acid permeance. This study tested four commercially available nanofiltration membranes (NF270, MPF-36, Toray NF, and Alfa Laval NF). Nanofiltration experiments were performed to investigate the rejection levels of lactic acid from a binary solution by using distinct molecular weight cut off membranes. All of the experiments were conducted with a lab-scale cross-flow membrane unit. Different operating conditions (pH, temperature) were studied for each membrane; the optimal process condition was found at 25 °C and pH 2.8. With higher temperatures and pH, an increase in LA rejection was observed. The MPF-36 membrane shows the lowest lactic acid rejection yield of 7%, while NF270 has the highest rejection yield of 71% at 25 °C and pH 2.8. These results will be helpful in the future to understand both the interaction of lactic acid permeance through nanofiltration membranes and process scale-up.

Potential utilization of dairy industries by-products and wastes through microbial processes: A critical review

The dairy industry generates excessive amounts of waste and by-products while it gives a wide range of dairy products. Alternative biotechnological uses of these wastes need to be determined to aerobic and anaerobic treatment systems due to their high chemical oxygen demand (COD) levels and rich nutrient (lactose, protein and fat) contents. This work presents a critical review on the fermentation-engineering aspects based on defining the effective use of dairy effluents in the production of various microbial products such as biofuel, enzyme, organic acid, polymer, biomass production, etc. In addition to microbial processes, techno-economic analyses to the integration of some microbial products into the biorefinery and feasibility of the related processes have been presented. Overall, the inclusion of dairy wastes into the designed microbial processes seems also promising for commercial approaches. Especially the digestion of dairy wastes with cow manure and/or different substrates will provide a positive net present value (NPV) and a payback period (PBP) less than 10 years to the plant in terms of biogas production.

Recovery of Salts from Synthetic Erythritol Culture Broth via Electrodialysis: An Alternative Strategy from the Bin to the Loop

Sustainability and circularity are currently two relevant drivers in the development and optimisation of industrial processes. This study assessed the use of electrodialysis (ED) to purify synthetic erythritol culture broth and for the recovery of the salts in solution, for minimising the generation of waste by representing an efficient alternative to remove ions, ensuring their recovery process contributing to reaching cleaner standards in erythritol production. Removal and recovery of ions was evaluated for synthetic erythritol culture broth at three different levels of complexity using a stepwise voltage in the experimental settings. ED was demonstrated to be a potential technology removing between 91.7–99.0% of ions from the synthetic culture broth, with 49–54% current efficiency. Besides this, further recovery of ions into the concentrated fraction was accomplished. The anions and cations were recovered in a second fraction reaching concentration factors between 1.5 to 2.5 times while observing low level of erythritol losses (<2%), with an energy consumption of 4.10 kWh/m3.

From the culture broth to the erythritol crystals: an opportunity for circular economy

Abstract

The reduction of sugar intake by adults has been stated by the World Health Organization as an important strategy to reduce the risk of non-communicable diseases. Erythritol is a four-carbon sugar alcohol that is considered as a highly suitable substitution for sucrose. This review article covers approaches for the separate stages of the biotechnological production of erythritol from cultivation to the downstream section. The first part focuses on the cultivation stage and compares the yields of erythritol and arising by-products achieved with different types of substrates (commercial versus alternative ones). The reported numbers obtained with the most prominently used microorganisms in different cultivation methods (batch, fed-batch or continuous) are presented. The second part focuses on the downstream section and covers the applied technologies for cell removal, recovery, purification and concentration of erythritol crystals, namely centrifugation, membrane separation, ion and preparative chromatography, crystallization and drying. The final composition of the culture broth and the preparative chromatography separation performance were identified as critical points in the production of a high-purity erythritol fraction with a minimum amount of losses. During the review, the challenges for a biotechnological production of erythritol in a circular economy context are discussed, in particular regarding the usage of sustainable resources and minimizing waste streams.

Key points

• Substitution of sucrose by erythritol can be a step towards a healthier society

• Biotechnological production of erythritol should follow a circular economy concept

• Culture broth composition and preparative chromatography are keys for downstreaming

• Substrate, mother liquor and nutrients are challenges for circular economy

A simple downstream processing protocol for the recovery of lactic acid from the fermentation broth

Lactic acid is one of the essential platform chemicals, and despite the availability of a range of downstream processes, its effective recovery is still elusive. A phase partitioning process using n-butanol and a chaotropic salt ammonium sulphate was developed to recover lactic acid from the fermentation broth of Lactobacillus pentosus SKL-18. During the optimization of various process parameters, the extraction medium's pH was found to be critical, with 2.5 being the best. The optimized process resulted in a lactic acid yield of 86% and found it to be 93% pure. The purity and characteristics of lactic acid were confirmed by FTIR and NMR spectra. This solvent-based extraction procedure is an economical and straightforward downstream process for purifying lactic acid produced from agro- and bakery-residues. The pure lactic acid can further be used for enzymatic synthesis of high value-added product PLA, a biodegradable and biocompatible plastics.

Resource recovery and circular economy from organic solid waste using aerobic and anaerobic digestion technologies

With the inevitable rise in human population, resource recovery from waste stream is becoming important for a sustainable economy, conservation of the ecosystem as well as for reducing the dependence on the finite natural resources. In this regard, a bio-based circular economy considers organic wastes and residues as potential resources that can be utilized to supply chemicals, nutrients, and fuels needed by mankind. This review explored the role of aerobic and anaerobic digestion technologies for the advancement of a bio-based circular society. The developed routes within the anaerobic digestion domain, such as the production of biogas and other high-value chemicals (volatile fatty acids) were discussed. The potential to recover important nutrients, such as nitrogen through composting, was also addressed. An emphasis was made on the innovative models for improved economics and process performance, which include co-digestion of various organic solid wastes, recovery of multiple bio-products, and integrated bioprocesses.

Fermentation Titer Optimization and Impact on Energy and Water Consumption during Downstream Processing

A common focus of fermentation process optimization is the product titer. Different strategies to boost fermentation titer target whole-cell biocatalyst selection, process control, and medium composition. Working at higher product concentrations reduces the water that needs to be removed in the case of aqueous systems and, therefore, lowers the cost of downstream separation and purification. Different approaches to achieve higher titer in fermentation are examined. Energy and water consumption data collected from different Cargill fermentation plants, i.e., ethanol, lactic acid, and 2-keto-L-gulonic acid, confirm that improvements in fermentation titer play a decisive role in downstream economics and environmental footprint.