On-line monitoring of continuous beer fermentation process using automatic membrane inlet mass spectrometric system

A fully automatic membrane inlet mass spectrometric (MIMS) on-line instrumentation for the analysis of aroma compounds in continuous beer fermentation processes was constructed and tested. The instrumentation includes automatic filtration of the sample stream, flushing of all tubing between samples and pH control. The calibration standards can be measured periodically. The instrumentation has also an extra sample line that can be used for off-line sample collection or it can be connected to another on-line method. Detection limits for ethanol, acetic acid and eight organic beer aroma compounds were from μg l⁻¹ to low mg l⁻¹ levels and the standard deviations were less than 3.4%. The method has a good repeatability and linearity in the measurement range. Response times are shorter than or equal to 3 min for all compounds except for ethyl caproate, which has a response time of 8 min. In beer aroma compound analysis a good agreement between MIMS and static headspace gas chromatographic (HSGC) measurements was found. The effects of different matrix compounds commonly present in the fermentation media on the MIMS response to acetaldehyde, ethyl acetate and ethanol were studied. Addition of yeast did not have any effect on the MIMS response of ethanol or ethyl acetate. Sugars, glucose and xylose, increased the MIMS response of all studied analytes only slightly, whereas salts, ammonium chloride, ammonium nitrate and sodium chloride, increased the MIMS response of all three studied compounds prominently. The system was used for on-line monitoring of continuous beer fermentation with immobilised yeast. The results show that with MIMS it is possible to monitor the changes in the continuous process as well as delays in the two-phase process.     

Rapid fermentation of beer using an immobilized yeast multistage bioreactor system

A multistage bioreactor system for rapid beer fermentation was developed. The main fermentation process, which conventionally requires 7 d, could be shortened to 2 d by this system. The concentration of esters and higher alcohols are major factors in brewery fermentation, their production being closely related to the yeast growth phase. Yeast metabolism was successfully subdivided into a growth and a restricted phase through a combination of a continuous stirredtank reactor (CSTR) and an immobilized yeast packed-bed reactor (PBR). Production of higher alcohols was high in the CSTR because of its association with the level of biosynthetic activityde novo. A small amount was also produced in the PBR, however, possibly a result of an overflow in carbohydrate metabolism. Ester formation mainly occurred in the PBR, a linear increase in the level of ester being observed with flow through the PBR. The reactor system control strategy was to maximize the level of both higher alcohol and ester formation. The CSTR/PBR control range, based on extract consumption, was varied between 1:1 and 1:2. A ratio of 1:1 tended to create a flat beer, whereas a ratio 1:2 gave a beer of richer quality. Amino acid uptake by the yeast directly contributed to a reduction in the wort pH, whereas no relation could be observed between the level of organic acid production and pH.     

Modeling of saccharide utilization in primary beer fermentation with yeasts immobilized in calcium alginate

Immobilized beer fermentation was studied using an industrial bottom-fermenting yeast strain Saccharomyces cerevisiae. The yeast cells were immobilized in 2.5% calcium alginate gel and used for brewing in a five-vessel cascade reactor. The fermentation was performed at 15°C at various flow rates. A nonstructured mathematical model was developed to simulate the performance of continuous primary fermentation of lager beer. The model was based on the following variables: maltose, maltotriose, glucose, fructose, ethanol, and cell concentration. Experimental values of these variables were determined in samples taken at regular intervals. For experimental data fitting a nonlinear regression was used. Substrate consumption was characterized by specific substrate consumption rate and saturation constant. The values of these two parameters were optimized for all four substrates. Inhibition effects of substrates and product were analyzed using various inhibition patterns. Only the inhibition effect of maltose on maltose consumption was clearly identified. A good-fitting relationship for maltose inhibition was found, and inhibition constants were calculated.     

Development of continuous fermentation using immobilized yeast cells for wine cooler process development

The continuous wine fermentation process, which employs a newly designed tapered column type bioreactor and immobilized yeast cells (Montrachet 522), was studied and its fermentation performance was compared with batch and suspended cell continuous wine fermentation systems. It was found that a stable continuous culture fermentation process could be maintained for a period of 2–3 mo when the new bioreactor system packed with immobilized yeast cells was employed. The new bioreactor containing immobilized yeast cells performed significantly better than the suspended cell culture system or batch culture. The effluent wine from the continuous fermentor system contained 7.1% (v/v) ethanol and 0.18% (w/v) residual sugar at 0.01 h^-1 dilution rate. The new continuous bioreactor system also gave 17–34 times higher maximum ethanol productivity compared to the conventional batch wine fermentation. At a low dilution rate, 0.01^-1, as high as 92% sugar to ethanol yield was achieved. Based on the results obtained from this study, the possibility of developing a continuous wine cooler fermentation process was demonstrated. A two-stage continuous wine fermentation system may be designed and operated. The grape juice can be fed into the first-stage that is operated at about 0.2 h^-1 dilution rate and the effluent from the first-stage is fed into the second-stage continuous fermentor operated at about 0.01 h^-1 dilution rate. By doing so, a wine cooler can be produced continuously and efficiently, by employing the newly designed tapered column type bioreactor charged with the immobilized yeast cells.     

The Effect of Sound Frequency and Intensity on Yeast Growth,Fermentation Performance and Volatile Composition of Beer

This study investigated the impact of varying sound conditions (frequency and intensity) on yeast growth, fermentation performance and production of volatile organic compounds (VOCs) in beer. Fermentations were carried out in plastic bags suspended in large water-filled containers fitted with underwater speakers. Ferments were subjected to either 200–800 or 800–2000 Hz at 124 and 140 dB @ 20 µPa. Headspace solid-phase microextraction (HS-SPME) coupled with gas chromatography-mass spectrometry (GC-MS) was used to identify and measure the relative abundance of the VOCs produced. Sound treatment had significant effects on the number of viable yeast cells in suspension at 10 and 24 h (p < 0.05), with control (silence) samples having the highest cell numbers. For wort gravity, there were significant differences between treatments at 24 and 48 h, with the silence control showing the lowest density before all ferments converged to the same final gravity at 140 h. A total of 33 VOCs were identified in the beer samples, including twelve esters, nine alcohols, three acids, three aldehydes, and six hop-derived compounds. Only the abundance of some alcohols showed any consistent response to the sound treatments. These results show that the application of audible sound via underwater transmission to a beer fermentation elicited limited changes to wort gravity and VOCs during fermentation.     

Rapid fermentation of beer using an immobilized yeast multistage bioreactor

The characteristics of yeast sulfite metabolism in a multistage bioreactor system for beer fermentation were investigated. No sulfite was produced in the continuous stirred-tank reactor (CSTR). However, large amounts were produced in the packed-bed reactor (PBR). Production of sulfite in the PBR seems to be inevitable when it is operated continuously. In order to control the sulfite level in the young beer, the yeast needs to be reactivated into the growth phase. One possible strategy to achieve this is to aerate and periodically remove yeast clogged in the reactor once every 6–7 months before the sulfite level exceeds a given concentration (e.g., 20 mg/L). It was confirmed that sulfite production is closely related to the growth condition of the yeast and is therefore important to consider in the control strategy for sulfite when using the immobilized yeast reactor for beer production.     

Production of Ethanol from Sweet Sorghum Juice Using VHG Technology: A Simulation Case Study

The aims of this study were to develop the kinetic model and determine kinetic parameters describing ethanol production from sweet sorghum juice using very high gravity technology in the batch fermentation of Saccharomyces cerevisiae NP01. The obtained experimental data were tested with four different types of model, based on the experimental data, accounting for the substrate limitation, substrate inhibition, product inhibition, and the combination of those three effects, respectively. The optimization technique to find kinetic parameters was non-linear regression using Marquardt method performed through numerical procedure. The chosen model with its kinetic parameters obtained in the batch mode was validated and tested against the other independent experimental data in the small batch-scale and large-scale fermenter, in order to investigate the applicability and scale-up effect of the model, respectively. Then, the obtained model with its parameters was applied in the simulations of the continuous and fed-batch operations to examine the concentration profiles of fermentation components with the variations in operating parameters such as the dilution rate, feed-flow rate, start-up time, and feed concentration. The results indicated that the kinetic model (the substrate limitation with substrate and product inhibition effects) was suitable to describe ethanol fermentation. In the continuous mode, using the dilution rate of 0.01 h^?1, the maximum ethanol concentration obtained was, approximately, 90 g/l whereas the simulated results from the fed-batch operation revealed that the maximum ethanol concentration at quasi-steady state condition was, approximately, 96 g/l. The start-up time of 21 h was the fastest time to reach the steady-state and quasi-steady state for both the continuous and fed-batch modes, respectively.     

Production of fuel ethanol from rye and triticale by very-high-gravity (VHG) fermentation

Very-high-gravity (VHG) rye and triticale mashes, containing about 28.5 g dissolved solids/100 mL of mash supernatant, were prepared by adjusting water:grain ratios to 2:1. Because of high viscosity, which develops during mashing, it was necessary to pretreat ground rye-water slurries with viscosity-reducing enzymes. There were no viscosity problems during the preparation of triticale mashes. Fermentations were conducted at 20°C, with and without 16 mM urea as a nitrogenous supplement. All fermentations were completed within 120–144 h. Supplementation with urea shortened the times required for completion of fermentation by 33% for triticale and by 40% for rye. The fermentation efficiencies for both grains ranged between 90 and 93%. These values are comparable to those reported for wheat, implying competitiveness of rye and triticale as fermentation feedstocks to replace wheat. The final ethanol yields were 409 L for rye and 417–435 L for triticale/t (dry basis). For a given size of fermentation vessel, 33% more grain was used in the VHG fermentation process than in normal gravity fermentation. This resulted in a 35–56% increase in ethanol concentration in the beer, when fermentors were filled to a constant volume. The corresponding reduction in water use by about one-third would result in savings in energy consumption in mash heating, mash cooling, and ethanol distillation. Fermentation efficiencies and final ethanol yields obtained per unit weight of grain fermented were not significantly different from the normal gravity fermentations.     

Effects of Wort Gravity and Nitrogen Level on Fermentation Performance of Brewer’s Yeast and the Formation of Flavor Volatiles

Normal gravity wort and high gravity wort with different nitrogen levels were used to examine their effects on the fermentation performance of brewer’s yeast and the formation of flavor volatiles. Results showed that both the wort gravity and nitrogen level had significant impacts on the growth rate, viability, flocculation, and gene expression of brewer’s yeast and the levels of flavor volatiles. The sugar (glucose, maltose, and maltotriose) consumption rates and net cell growth decreased when high gravity worts were used, while these increased with increasing nitrogen level. Moreover, high gravity resulted in lower expression levels of ATF1, BAP2, BAT1, HSP12, and TDH, whereas the higher nitrogen level caused higher expression levels for these genes. Furthermore, the lower nitrogen level resulted in increases in the levels of higher alcohols and esters at high wort gravity. All these results demonstrated that yeast physiology and flavor balance during beer brewing were significantly affected by the wort gravity and nitrogen level.     

Electrospray ionization mass spectrometry fingerprinting of beer

After just simple degassing, dilution, pH adjustment and direct flow injection, characteristic fingerprint spectra of beer samples have been obtained by fast (few seconds) electrospray ionization mass spectrometry (ESI-MS) analysis in both the negative and positive ion modes. A total of 29 samples belonging to the two main beer types (lagers and ales) and several beer subtypes from USA, Europe and Brazil could be clearly divided into three groups both by simple visual inspection of their ESI(+)-MS and ESI(-)-MS fingerprints as well as by chemometric treatment of the MS data. Diagnostic ions with contrasting relative abundances in both the positive and negative ion modes allow classification of beers into three major types: P = pale (light) colored (pilsener, pale ale), D = dark colored (bock, stout, porter, mild ale) and M = malt beer. For M beers, samples of a dark and artificially sweetened caramel beer produced in Brazil and known as Malzbiers were used. ESI-MS/MS on these diagnostic beer cations and anions, most of which are characterized as arising from ionization of simple sugars, oligosaccharides, and iso-alpha-acids, yield characteristic tandem mass spectra adding a second and optional MS dimension for improved selectivity for beer characterization by fingerprinting. Direct ESI-MS or ESI-MS/MS analysis can therefore provide fast and reliable fingerprinting characterization of beers, distinguishing between types with different chemical compositions. Other unusual polar components, impurities or additives, as well as fermentation defects or degradation products, could eventually be detected, making the technique promising for beer quality control.     

Quantification of organic acids in beer by nuclear magnetic resonance (NMR)-based methods

The organic acids present in beer provide important information on the product's quality and history, determining organoleptic properties and being useful indicators of fermentation performance. NMR spectroscopy may be used for rapid quantification of organic acids in beer and different NMR-based methodologies are hereby compared for the six main acids found in beer (acetic, citric, lactic, malic, pyruvic and succinic). The use of partial least squares (PLS) regression enables faster quantification, compared to traditional integration methods, and the performance of PLS models built using different reference methods (capillary electrophoresis (CE), both with direct and indirect UV detection, and enzymatic essays) was investigated. The best multivariate models were obtained using CE/indirect detection and enzymatic essays as reference and their response was compared with NMR integration, either using an internal reference or an electrical reference signal (Electronic REference To access In vivo Concentrations, ERETIC). NMR integration results generally agree with those obtained by PLS, with some overestimation for malic and pyruvic acids, probably due to peak overlap and subsequent integral errors, and an apparent relative underestimation for citric acid. Overall, these results make the PLS-NMR method an interesting choice for organic acid quantification in beer.     

Evaluation of beer deterioration by gas chromatography-mass spectrometry/multivariate analysis: a rapid tool for assessing beer composition

Beer stability is a major concern for the brewing industry, as beer characteristics may be subject to significant changes during storage. This paper describes a novel non-targeted methodology for monitoring the chemical changes occurring in a lager beer exposed to accelerated aging (induced by thermal treatment: 18 days at 45 °C), using gas chromatography-mass spectrometry in tandem with multivariate analysis (GC-MS/MVA). Optimization of the chromatographic run was performed, achieving a threefold reduction of the chromatographic time. Although losing optimum resolution, rapid GC runs showed similar chromatographic profiles and semi-quantitative ability to characterize volatile compounds. To evaluate the variations on the global volatile signature (chromatographic profile and m/z pattern of fragmentation in each scan) of beer during thermal deterioration, a non-supervised multivariate analysis method, Principal Component Analysis (PCA), was applied to the GC-MS data. This methodology allowed not only the rapid identification of the degree of deterioration affecting beer, but also the identification of specific compounds of relevance to the thermal deterioration process of beer, both well established markers such as 5-hydroxymethylfufural (5-HMF), furfural and diethyl succinate, as well as other compounds, to our knowledge, newly correlated to beer aging.     

Importance of growth form on production of hybrid antibiotic byStreptomyces lividans TK21 by fed-batch and continuous fermentation

A fermentation strategy, based on the controlled feeding of growthlimiting nutrients in order to maintain metabolic activity for extended periods, has been examined in the case of the production of a hybrid antibiotic by a transformed strain ofStreptomyces lividans TK21. The fed-batch operation did not improve the results obtained with batch operation. Continuous cultures on defined medium showed stable levels of biomass concentration, but antibiotic production ceased when continuous operation was started. The results obtained indicate the critical influence that morphology of the cell aggregates has on metabolic activity. The antibiotic is produced only in culture conditions providing growth in compact mycelial pellets.     

Yeast cells,beer composition and mean pore diameter impacts on fouling and retention during cross-flow filtration of beer with ceramic membranes

Clarification of rough beer (RB) and pasteurisation of clarified beer (CB) by cross-flow microfiltration (CFMF) stand as potential applications of membranes in the food industry. This study is based on the comparison of the resistances to mass transfer obtained during the filtration of RB and CB. Empirical correlations made it possible to calculate the CB resistances for the same conditions of transmembrane pressure and cross-flow velocity as for the RB filtration runs. The 1.4 μm membrane led to much lower resistances than the other membranes because of the lower retention rates of the beer compounds such as proteins and polyphenols. In this case, the predominant fouling mechanism was due to the yeast cell layer which was very sensitive to cross-flow velocity. On the other hand, with the 0.1, 0.45 and 0.8 μm membranes, the retention or adsorption of the CB compounds, such as proteins and polyphenols was the predominant mechanism. The resistances obtained with the rough and CB were fairly similar. We assume that the presence of yeast cells lead to less compact proteins and polyphenols fouling.     

Analysis of saccharides in beer samples by flow injection with electrospray mass spectrometry

Saccharides in foods play important roles, as they are essential substrates for fermentation processes. In brewing, the concentration of maltooligosaccharides influences the characteristics of beers and therefore their determination is of great practical interest. Electrospray ionization mass spectrometry (ESI-MS) was applied to identify and characterise maltooligosaccharides in beer samples. The effects due to different cation concentrations and dilution of samples were studied. Furthermore, quantitative analyses of maltooligosaccharides by means of flow-injection ESI-MS (FI/ESI-MS) of 1-microL beer samples (diluted 1000-fold) are described.     

The influence of additives on beer stability investigated by EPR spectroscopy

In thermally-accelerated aging followed by EPR spectroscopy of beer samples of various stabilities, free radical 4-hydroxy-2,2,6,6-tetramethyl-1-piperidinyloxy (TEMPOL) was shown to be an effective indicator of the breakdown of a sample's stability, comparable to the commonly used spin trapping agent alpha-phenyl-N-tert-butylnitrone (PBN). Both indicators were then employed to investigate the influence of additives on beer stability. The addition of L-ascorbic acid (ASC) to the beer samples accelerated the radical processes and a lower stability was found. DL-alpha-tocopherol (alpha-TOC) did not influence beer stability significantly (probably due to its limited solubility). Na2SO3, described as a very effective stabilizer in experiments with the PBN spin trap, was found not to be effective using the TEMPOL indicator. This is probably due to inhibition in the formation of spin adducts or their degradation by Na2SO3.     

An automated flow-injection extraction method for determination of bittering compounds in beer

The manual standard liquid-liquid extraction method for determining bitterness in beer is adapted for a flow-injection extraction system. With the flow-injection method, the separate solvent blank extraction required in the batch procedure is unnecessary. The injected sample volume is 100 μl, the sampling frequency is about 60 h^?1 and the consumption of iso-octane is only about 1 ml/sample.     

超高效液相色谱-串联质谱法检测麦汁和啤酒中的麦香风味物质

应用超高效液相色谱-串联质谱(UPLC-MS/MS)技术定量检测了啤酒和麦汁中的2,5-二甲基-4-羟基-3(2H)-呋喃酮(DMHF)、2(或5)-乙基-5(或2)-甲基-4-羟基-3(2H)-呋喃酮(EMHF)和2-乙酰吡咯(2-AP)3种麦香风味物质。使用C₁₈固相萃取柱净化样品。采用ACQUITY UPLC HSS T3色谱柱(50 mm×2.1 mm, 1.8 μm)分离,以0.1%(v/v)甲酸水溶液和0.01%(v/v)甲酸乙腈溶液为流动相进行梯度洗脱。结合这3种化合物的保留时间,在正离子模式下,采用多反应监测(MRM)技术进行定量检测。当质量浓度低于1000 μ g/L时,校准曲线的线性良好(R²>0.999)。方法的加标回收率在74.3%~86.7%之间,相对标准偏差(RSD,n=6)在4.8%~7.3%之间。由于酵母发酵时会生成DMHF和EMHF,导致啤酒中这两种物质的含量明显高于麦汁。某些品类啤酒如印度淡色爱尔啤酒(IPA),通常含有较高的麦香风味物质。该法样品处理简单,选择性好,且灵敏、准确、重现性好,可用于啤酒生产的过程控制。     

Continuous production of butanol from starch-based packing peanuts

Acetone, butanol, ethanol (ABE, or solvents) were produced from starch-based packing peanuts in batch and continuous reactors. In a batch reactor, 18.9 g/L of total ABE was produced from 80 g/L packing peanuts in 110 h of fermentation. The initial and final starch concentrations were 69.6 and 11.1 g/L, respectively. In this fermentation, ABE yield and productivity of 0.32 and 0.17 g/(L·h) were obtained, respectively. Compared to the batch fermentation, continuous fermentation of 40 g/L of starch-based packing peanuts in P2 medium resulted in a maximum solvent production of 8.4 g/L at a dilution rate of 0.033 h⁻¹. This resulted in a productivity of 0.27 g/(L·h). However, the reactor was not stable and fermentation deteriorated with time. Continuous fermentation of 35 g/L of starch solution resulted in a similar performance. These studies were performed in a vertical column reactor using Clostridium beijerinckii BA101 and P2 medium. It is anticipated that prolonged exposure of culture to acrylamide, which is formed during boiling/autoclaving of starch, affects the fermentation negatively.     

The Operable Modeling of Simultaneous Saccharification and Fermentation of Ethanol Production from Cellulose

An operable batch model of simultaneous saccharification and fermentation (SSF) for ethanol production from cellulose has been developed. The model includes four ordinary differential equations that describe the changes of cellobiose, glucose, yeast, and ethanol concentrations with respect to time. These equations were used to simulate the experimental data of the four main components in the SSF process of ethanol production from microcrystalline cellulose (Avicel PH101). The model parameters at 95% confidence intervals were determined by a MATLAB program based on the batch experimental data of the SSF. Both experimental data and model simulations showed that the cell growth was the rate-controlling step at the initial period in a series of reactions of cellulose to ethanol, and later, the conversion of cellulose to cellobiose controlled the process. The batch model was extended to the continuous and fed-batch operating models. For the continuous operation in the SSF, the ethanol productivities increased with increasing dilution rate, until a maximum value was attained, and rapidly decreased as the dilution rate approached the washout point. The model also predicted a relatively high ethanol mass for the fed-batch operation than the batch operation.