Novel Technology Development through Thermal Drying of Encapsulated Kluyveromyces marxianus in Micro- and Nano-tubular Cellulose in Lactose Fermentation and Its Evaluation for Food Production

A novel technology development based on the production of a low-cost starter culture for ripening of cheeses and baking is reported in the present study. The starter culture comprises thermally dried cells of Kluyveromyces marxianus encapsulated in micro- and nano-tubular cellulose. For production of a low-cost and effective biocatalyst, whey was used as raw material for biomass production and thermal drying methods (convective, conventional, and vacuum) were applied and evaluated at drying temperatures ranging from 35 to 60?°C. The effect of drying temperature of biocatalysts on fermentability of lactose and whey was evaluated. Storage stability and suitability of biocatalysts as a commercial starter cultures was also assessed and evaluated. All thermally dried biocatalysts were found to be active in lactose and whey fermentation. In all cases, there was sugar conversion ranging from 92 to 100?%, ethanol concentration of up to 1.47?% (v/v), and lactic acid concentrations ranged from 4.1 to 5.5?g/l. However, convective drying of the encapsulated cells of K. marxianus in micro- and nano-tubular cellulose was faster and a more effective drying method while drying at 42?°C appear to be the best drying temperature in terms of cell activity, ethanol, and lactic acid formation. Storage of the biocatalysts for 3?months at 4?°C proved maintenance of its activity even though fermentation times increased by 50?C100?% compared with the fresh dried ones.     

Volatiles Formation from Grape Must Fermentation Using a Cryophilic and Thermotolerant Yeast

Grape must fermentation performance and volatiles formation by simultaneously cryophilic and thermotolerant yeast (strain AXAZ-1), isolated from grapes in Greece, was evaluated in a wide temperature range (5?C40°C). Yeast strain was immobilized on brewer??s spent grains (BSG) and the formed biocatalyst was introduced into a Multi-Stage Fixed Bed Tower (MFBT) bioreactor. Almost complete sugar utilization from the aforementioned biocatalyst was observed in a wide temperature spectrum, ranging from 5?°C to 37?°C, while at 40?°C residual sugar was up to 29?g/l. Time to complete fermentation with the immobilized yeast ranged from 290?h at 5?°C and 120?h at 40?°C to 25?h at 33?°C. The daily ethanol productivity reached maximum (88.6?g/l) and minimum (5.6?g/l) levels at 33?°C and 5?°C, respectively. The aroma-related compounds?? profiles of immobilized cells at different fermentation temperatures were evaluated by using solid phase microextraction (SPME) gas chromatography/mass spectrometry (GC/MS). Must fermentation resulted in a high-quality fermentation product due to the low concentrations of higher and amyl alcohols at all temperatures tested. AXAZ-1 is a very promising strain for quality wine production, as it is capable of performing fermentations of high ethanol concentration and productivities in both low and high temperatures.     

Scale-up of Thermally Dried Kefir Production as Starter Culture for Hard-Type Cheese Making: An Economic Evaluation

This paper concerns the effect of thermal-drying methodology on the investment cost for dried kefir cells production in order to be used as starter culture in cheese manufacturing. Kefir cells were produced at pilot plant scale using a 250-L bioreactor and whey as the main substrate. Kefir cells were subsequently dried in a thermal dryer at 38?°C and used as a starter culture in industrial-scale production of hard-type cheeses. The use of thermally dried kefir as starter culture accelerated ripening of cheeses by increasing both lipolysis and fermentation rate as indicated by the ethanol, lactic acid, and glycerol formation. Additionally, it reduced coliforms and enterobacteria as ripening proceeded. This constituted the basis of developing an economic study in which industrial-scale production of thermally dried kefir starter culture is discussed. The industrial design involved a three-step process using three bioreactors of 100, 3,000, and 30,000 L for a plant capacity of 300 kg of thermally dried kefir culture per day. The cost of investment was estimated at 238,000 €, which is the 46% of the corresponding cost using freeze-drying methodology. Production cost was estimated at 4.9 €/kg of kefir biomass for a 300-kg/day plant capacity, which is the same as with the corresponding cost of freeze-dried cells. However, the estimated added value is up to 10.8?×?10⁹ € within the European Union.