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Economic Analysis of the Production of Amylases and Other Hydrolases by Aspergillus awamori in Solid-State Fermentation of Babassu Cake.

de Castro AM, Carvalho DF, Freire DM, Dos Reis Castilho L - Enzyme Res (2010)

Bottom Line: A first evaluation showed a large impact of the inoculum propagation medium on production costs.Therefore, five propagation media were compared, and PDA medium presented the best cost-benefit ratio.The credits obtained from sales of fermented cake as a coproduct enabled a significant decrease in the production cost of the enzyme product, down to 10.40 USD kg(-1).

View Article: PubMed Central - PubMed

Affiliation: Renewable Energy Division, Research and Development Center, PETROBRAS, Avenue Horácio Macedo, 950 Ilha do Fundão, Rio de Janeiro 21941-915, Brazil.

ABSTRACT
Amylases are one of the most important industrial enzymes produced worldwide, with their major application being in ethanol manufacturing. This work investigated the production of amylases by solid-state fermentation of babassu cake, using the filamentous fungus Aspergillus awamori IOC-3914. Lab-scale experiments were carried out to generate input data for simulations of an industrial plant for amylase production. Additionally to the target enzymes, other hydrolases (cellulases, xylanases, and proteases) were also produced, enriching the final product. The most suitable fermentation time was 144 hours, when exoamylase and endoamylase activities of 40.5 and 42.7 U g(-1) were achieved, respectively. A first evaluation showed a large impact of the inoculum propagation medium on production costs. Therefore, five propagation media were compared, and PDA medium presented the best cost-benefit ratio. The credits obtained from sales of fermented cake as a coproduct enabled a significant decrease in the production cost of the enzyme product, down to 10.40 USD kg(-1).

No MeSH data available.


Equipment occupancy chart of an industrial plant for production of amylases and accessory enzymes considering 144 hours of fermentation, before (a) and after (b) debottlenecking analysis. White bars represent occupancy during first batch, while light grey and dark grey bars represent the occupancy during second and third batches, respectively. For abbreviations, see “list of symbols and abbreviations”.
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fig3: Equipment occupancy chart of an industrial plant for production of amylases and accessory enzymes considering 144 hours of fermentation, before (a) and after (b) debottlenecking analysis. White bars represent occupancy during first batch, while light grey and dark grey bars represent the occupancy during second and third batches, respectively. For abbreviations, see “list of symbols and abbreviations”.

Mentions: Simulations and throughput analysis confirmed experimental observations indicating that the inoculum propagation step was a bottleneck of the process. Its total duration per batch was 172 hours (slightly more than 7 days, because its operation includes charge of nutrients, cells, water and CIP), so the other sections of the plant had idle periods, and their starting times were determined by the inoculum propagation stage, as a master-slave relationship. For this reason, a debottlenecking methodology was conducted and indicated that one extra inoculum propagation fermenter should be included in the plant (operating in a stagger mode), so that it would initiate its operation a shift time after the first inoculum propagation unit. Considering such modification, the main fermenter, which was 22 times larger than the inoculum propagation unit, had its idle time reduced from 15% to 3.6% of its total operation time per batch (Figure 3).


Economic Analysis of the Production of Amylases and Other Hydrolases by Aspergillus awamori in Solid-State Fermentation of Babassu Cake.

de Castro AM, Carvalho DF, Freire DM, Dos Reis Castilho L - Enzyme Res (2010)

Equipment occupancy chart of an industrial plant for production of amylases and accessory enzymes considering 144 hours of fermentation, before (a) and after (b) debottlenecking analysis. White bars represent occupancy during first batch, while light grey and dark grey bars represent the occupancy during second and third batches, respectively. For abbreviations, see “list of symbols and abbreviations”.
© Copyright Policy - open-access
Related In: Results  -  Collection

Show All Figures
getmorefigures.php?uid=PMC2962910&req=5

fig3: Equipment occupancy chart of an industrial plant for production of amylases and accessory enzymes considering 144 hours of fermentation, before (a) and after (b) debottlenecking analysis. White bars represent occupancy during first batch, while light grey and dark grey bars represent the occupancy during second and third batches, respectively. For abbreviations, see “list of symbols and abbreviations”.
Mentions: Simulations and throughput analysis confirmed experimental observations indicating that the inoculum propagation step was a bottleneck of the process. Its total duration per batch was 172 hours (slightly more than 7 days, because its operation includes charge of nutrients, cells, water and CIP), so the other sections of the plant had idle periods, and their starting times were determined by the inoculum propagation stage, as a master-slave relationship. For this reason, a debottlenecking methodology was conducted and indicated that one extra inoculum propagation fermenter should be included in the plant (operating in a stagger mode), so that it would initiate its operation a shift time after the first inoculum propagation unit. Considering such modification, the main fermenter, which was 22 times larger than the inoculum propagation unit, had its idle time reduced from 15% to 3.6% of its total operation time per batch (Figure 3).

Bottom Line: A first evaluation showed a large impact of the inoculum propagation medium on production costs.Therefore, five propagation media were compared, and PDA medium presented the best cost-benefit ratio.The credits obtained from sales of fermented cake as a coproduct enabled a significant decrease in the production cost of the enzyme product, down to 10.40 USD kg(-1).

View Article: PubMed Central - PubMed

Affiliation: Renewable Energy Division, Research and Development Center, PETROBRAS, Avenue Horácio Macedo, 950 Ilha do Fundão, Rio de Janeiro 21941-915, Brazil.

ABSTRACT
Amylases are one of the most important industrial enzymes produced worldwide, with their major application being in ethanol manufacturing. This work investigated the production of amylases by solid-state fermentation of babassu cake, using the filamentous fungus Aspergillus awamori IOC-3914. Lab-scale experiments were carried out to generate input data for simulations of an industrial plant for amylase production. Additionally to the target enzymes, other hydrolases (cellulases, xylanases, and proteases) were also produced, enriching the final product. The most suitable fermentation time was 144 hours, when exoamylase and endoamylase activities of 40.5 and 42.7 U g(-1) were achieved, respectively. A first evaluation showed a large impact of the inoculum propagation medium on production costs. Therefore, five propagation media were compared, and PDA medium presented the best cost-benefit ratio. The credits obtained from sales of fermented cake as a coproduct enabled a significant decrease in the production cost of the enzyme product, down to 10.40 USD kg(-1).

No MeSH data available.