distilleries profitability maximization · fermentec and produced the yeast of choice for sugar...

Distilleries Profitability MaximizationYeast, Fermentation & Industrial Performances ImprovementsAIDA , Hyderabad, Oct 2016

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AgendaAgenda

Lesaffre & Leaf

Profitability Maximization

Fermentation BasicsFermentation Basics

Leaf Offer

© 2016 - ALL RIGHTS RESERVED

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LesaffreLesaffre


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LesaffreLesaffre

eba

l pre

senc

e

rong

R&

D

Turnover: 1,8 billion €. More than 60% is generated outside Europe, including over

Glo St

r

200 researchers in Lesaffre R&D center

40% on emerging markets

Presence in 40 countries: 55 production plants, 40 sales offices

Working with over 60 universities and research centers worldwide

plants, 40 sales offices

9300 employees representing more than 70 nationalities.


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Turning science into industrial realityTurning science into industrial reality

We are the business unit of Lesaffre focusing on the worldwideWe are the business unit of Lesaffre, focusing on the worldwide development and sales of value-added fermentation solutions for fuel ethanol, industrial alcohol and bio-based chemicals producers.

Our mission:

Offer value added fermentation products to the first generation fuel ethanol & industrial alcohol producers

Continue innovating in the field of lignocellulosic ethanol.

Develop economically viable solutions for bio-based chemicals producers.


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Our milestonesOur milestones

Launch of Ethanol Red® dry yeast that

Launch of Ethanol Red® Cream and

Beginning of R&D works for

Sadistil™ Plusa new yeast offer

Acquisition of the Xylose Isomerase

Commissioning of Crescentino plant

LeafAcquisition of

Jointdevelopment

FT 858 Lyeast ofy y

became the yeast of reference for starch

to ethanol producers

Propaide™ 2G ethanol yeasty

for sugar beet ethanol producers

ytechnology from

Butalco.Launch of CelluX™

pwith

CelluX™

qButalco

pagreement with

DDNA

yreference forsugar cane to

ethanolproduced and sold

under licencefrom Fermentec


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Profitability yMaximization

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Ethanol Plant Operating CostsEthanol Plant Operating CostsConsumables

h i

CAPEX Ammortisation

Labour7%

(Enzymes, Yeast, Chemicals…)5%

Feedstock51%

11%

51%

Energy26%26%


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Ethanol Plant ProfitabilityEthanol Plant ProfitabilityEthanol Plant Key Performance Indicators (KPI):• Yield Optimize raw material conversion to EtOH• Energy Optimize Energy at Distillation• Productivity Optimize Process time

Input Ingredient Savings

Profitability Maximization


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Fermentation basics

Yeast role in improving industrial performances improvements

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What is Yeast?What is Yeast?Many definitions for YEAST One of the best is:

Yeasts are relatively Sophisticated Living y p gUnicellular Fungi

Saccharomyces Yeast• Eukaryotes: (animals, …humans)• Larger than bacteria.• ~ 700 yeast species recognized/few well characterised• ~ 700 yeast species recognized/few well characterised.• > many thousands strains in Lesaffre collection• Specific shape, genetic properties, composition, physiological

t t

Schizosaccharomyces

state.


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Conditions determine how yeast divideConditions determine how yeast divide

Sporulation BuddingSporulation Budding

Division Meiosis Mitosis

Genome Rearranged Unchanged

C di i S N / M dConditions Stress No / Moderate stress

Purpose Adapt Colonize

Used in R&D (new strain development)Propagation / Fermentation


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Yeast Production ProcessYeast Production Process


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Active Dry YeastActive Dry Yeast

After Drying:A ti d t ll ti l f 1• Active dry yeast: small particles of approx. 1mm.

• They are vacuum-packed to preserve them from oxygen and moisture. Soft bags should be discarded.g

• 2 year shelf life from production date.• High storage temperature should be avoided


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Drying removes moisture from cellDrying removes moisture from cellY t D M ttYeast Dry Matter Before Drying:

20% (Liquid) to 35% (Solid)

Smooth cell surface.

Yeast Dry Matter After Drying:y g

94,0 % – 96,5 %

Uneven cell surface


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Uneven cell surface

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Biomass production needs oxygenBiomass production needs oxygen

Oxidative (used in producing industrial yeast).R i ORequires Oxygen.Maximizes biomass yields.Efficient conversion of sugar to biomassEfficient conversion of sugar to biomassPropagation


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Yeast PropagationYeast Propagation400

300

350

200

250

l Cou

nt

se ase

ase

150

200

Cell

g Ph

ase

nent

ial P

has

atio

nary

Ph

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ing

Pha

50

100 Lag

Expo

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Sta

De

0

0 10 20 30 40 50 60Time


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Anaerobic Ethanol ProductionAnaerobic Ethanol Production

Fermentative (used in ethanol production)O i li iti b tOxygen is limiting or absent.Occurs in excess sugarPoor biomass yields (not a problem : ethanol is the product)Poor biomass yields (not a problem : ethanol is the product)Ethanol and CO2 are the major by-products.


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Ethanol is not your only productEthanol is not your only product2nCH CHnC6H12O6

n(180 g/mol)

2nCH3CH2OH

n(92 g/mol)

2nCO2

• Theoretical Yield from Glucose to EtOH: 51.1% w/w (n92/n180)• Glucose also used by other metabolism pathwaysGlucose also used by other metabolism pathways

At Pitch End of Fermentation

Initial Mass (g) Conc. (g/kg) Final Mass (g)

Glucose 256 1.5 1.3

Carbon Dioxide 0 138.9 138.9

Ethanol 0 132 113.7

Gl l 0 9 7 8Glycerol 0 9 7.8

Biomass 0.25 7 6

Lactic Acid 0 0.5 0.4

Acetic Acid 0 0 1 0 1


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Acetic Acid 0 0.1 0.1

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Fermentation StressesFermentation Stresses


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Fermentation StressesFermentation Stresses - BacteriaEffect of Infection on YieldEffect of Infection on Yield

Infection level (bacteria/ml

Loss in Yield (%)

0-1 million Up to 1%

1-10 million 1-3%

10-100 million 3-5%

Over 100 million Over 5% Lactic acid inhibition > 0.2% w/w

Bacteria Growth: 4-6 times faster than Saccharomyces:

Over 100 million Over 5% /Acetic acid inhibition > 0.05% w/w

Bacteria Growth: 4-6 times faster than Saccharomyces:• Substrate Competition-Redirection: less sugar & nutrients for selected yeasts• Organic Acids Production: loss in EtOH Yield


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Fermentation StressesFermentation Stresses - BacteriaGrowth Rate Propagation

timeGeneration Multiplication

Yeast 2 h 8 h 4 16

Bacteria (Slow) 1 h 8 h 8 256

Bacteria (Fast) 0.5 h 8h 16 65536

• Microorganisms develop through divisions Each generation

( )

g p g gmultiplies the total count by 2.

• Bacteria faster than Yeast.P ti f th t i t d b t i f t• Propagation: race for the nutrient, and bacteria are faster.

• Clean conditions & sufficient yeast pitching rate required.


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Fermentation StressesFermentation Stresses - Nutrition

Different feedstocks + Variability

C47 H6.3 O33 N8 P1.2 Salts

y⇒ Need to adjust the nutrition

Yeast made of: 47 6.3 33 8 1.2 4.5

(= Normal Average Per Cent of Dry Matter)

• Macronutrient CHONP• Micronutrients: Minerals & Vitamins

d fi d h b h i h⇒ Need to find them both in Mash


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Fermentation StressesFermentation Stresses - Nutrition%Assimilation of a 150 g/L glucose solution %Assimilation of a 250 g/L glucose solution

6050

75

95

73.381

10090

100 100

44 44

60

No N Medium N High N24 Hours fermentation 48 Hours Fermentation

No N Medium N High N24 Hours fermentation 48 Hours Fermentation

Sources: CERIA 2003

• Assimilable Nitrogen: main limiting nutrient (VHG).• Higher sugar content higher FAN

Sources: CERIA 2003

Higher sugar content higher FAN.• Nitrogen sources could be: Urea, Liquid ammonia, Diammonium

sulfate (NH4)2SO4, DAP:(NH4)2HPO4


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Fermentation StressesFermentation Stresses - Temperature

Ethanol Red Performances at 36 oC (97°F) and 40 oC (104°F)

32°C 36°C 40°C

n (g/L)

at 36 oC (97 F) and 40 oC (104 F)

Dextrose 36oC

Glycerol 36oC

Ethanol

160 g/L 146 g/L 126 g/L

20% v/v 19% v/v 16% v/v

Concen

tratio

Ethanol 36oC

Dextrose 40oC

Glycerol 40 oC

Ethanol 40 oC

ResidualSugars (g/L)

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0 16 24 40 48 64

Source: University of Minnesota (Laboratory trials on corn mash 35% DS)

Glycerol (g/L)

10 13 14


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Leaf Offer

Managing Fermentation Stresses Operating best quality products

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Leaf OfferA global scientific approach is required:

Leaf Offerg pp q

We focus We provide We needon• Yeast

• Best Quality Products • Technical Support

• Confidentiality (NDA)• Commitment

• Fermentation

Profitability Maximization Industrial Performances Improvement


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Our ProductsOur ProductsEthanol Red®

• #1 yeast among first generation ethanol producers.• Tolerates high ethanol & temperature levels• Tolerates high ethanol & temperature levels.• Ideal for the production of industrial ethanol from Starch & Sugar.• Worldwide reference for Grain Industry.y

Distributed in India exclusively by Catalysts Biotechnologies


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NEW FT 858 LNEW – FT 858 L

Selected by Fermentec

and produced

The yeast of choice for sugar cane based fermentation

• Specifically selected in Brazil by Fermentec under industrial environment

and produced and sold

under licenceby Leaf

Specifically selected in Brazil by Fermentec under industrial environment.• High tolerance to alcohol.• High tolerance to temperature & organic acids stresses.• Ability to ferment at low pH.• Less foamingLess foaming.• Higher yield combined with low residual sugars.• Yeast of choice for cane-based fermentation (Cane Juices, Molasses).

Distributed in India exclusively by Catalysts BiotechnologiesDistributed in India exclusively by Catalysts Biotechnologies


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Turning science into industrial reality

Christophe Teste-Leaf Regional Technical Manager SEA

distilleries profitability maximization · fermentec and produced the yeast of choice for sugar...

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