INDUSTRIAL BIOTECHNOLOGY

Baker’s yeast production

PROF. DEBABRATA DAS

DEPARTMENT OF BIOTECHNOLOGY
IIT KHARAGPUR

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 Factors influencing the selection of Baker’s yeast

Selection of the organism

• Characteristics of the Baker’s yeast
• It should be genetically stable
• High fermenting power
• Rapid growth characteristics giving high yield in cheaper raw materials.
• Readily dispersed in water.
• Good appearance.
• Resistant to autolysis (i.e., it should have good keeping qualities specially during
storage)

Prof. Debabrata Das

Department of Biotechnology
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 Baker’s yeast
• Baker's yeast is the common name for the strains
of yeast commonly used as a leavening
agent in baking bread and bakery products

• It converts the fermentable sugars present in

the dough into carbon dioxide and ethanol.

• Baker's yeast is of the species Saccharomyces

cerevisiae, commonly used in alcoholic
fermentation, which is called brewer's yeast.

https://en.wikipedia.org/wiki/Baker%27s_yeast
http://www.e-xinghe.com/en/product.asp?bigclassname=PRODUCTS&smallclassname=BAKERS%20YEAST%20BRANDS https://youavang.wordpress.com/2013/07/17/yeast-face-masks-something-has-gone-a-rye

Prof. Debabrata Das

Department of Biotechnology 3
 Saccharomyces cerevisiae

• It is a eukaryotic organism
• Source of vitamins
• It has a high protein content( upto 50 %)
• Generation time of yeast : 80 – 100 min

https://phys.org/news/2013-11-bread-beer-national-yeast-cultures.html

Prof. Debabrata Das

Department of Biotechnology 4
 History of Baker’s yeast production
• First report about the Baker’s yeast was given by Mason (1792).
• Baker’s yeast was obtained as a byproduct in alcohol industry.
• Process was improved in 1860 which is known as Vienna process where
cereals were used to produce yeast
• During World War II, Fleischmann developed a granulated active dry yeast.
• Germans found out that cereal grains can be replaced by molasses present
in cane sugar.
• Particularly in Europe, the beet is used as a source of molasses.

Prof. Debabrata Das

Department of Biotechnology 5
 Yeast propagation
•In the absence of oxygen, yeast ferments sugars to form alcohol

•In the presence of oxygen, it propagates itself by budding.

http://biology-pictures.blogspot.in/2011/10/budding-yeast-picture.html

Prof. Debabrata Das

Department of Biotechnology 6
 Types of baker’s yeast
• Baker's yeast is classified on the basis of the moisture contents.
• Dry yeast forms are good choices for longer-term storage, often lasting more than a year at
room temperatures.
Types
Active dry yeast
• It consists of coarse granules of yeast, with live yeast cells encapsulated
in a thick jacket of dry, dead cells with some growth medium.
• It must first be rehydrated.
• It can be stored at room temperature for a year, or frozen for more than a decade,
• It is more sensitive than other forms to thermal shock when actually used in recipes.

http://www.lesaffre.com/activities/yeast-baking-solutions/yeasts/active-dried-yeast/

Prof. Debabrata Das

Department of Biotechnology 7
 Types of baker’s yeast
Cream yeast
• It is a suspension of yeast cells in liquid, siphoned.
• Primary use is in industrial bakeries with special high-volume dispensing
and mixing equipment
Deactivated yeast
• Dead yeast which has no leavening value.
• Used for pizza and pan bread doughs
• It is a powerful reducing agent used to increase the extensibility of a dough
http://www.vegkitchen.com/nutrition/nutritional-yeast-a-great-source-of-b12-and-other-b-vitamin

• It is a source of vitamins and it is of nutritional value.

Rapid-rise yeast
• It is a variety of dried yeast (usually a form of instant yeast) that is
of a smaller granular size.
• It dissolves faster in dough, and it provides greater carbon dioxide output to allow faster rising.

http://joepastry.com/2013/rapid-rise-yeast/

Prof. Debabrata Das

Department of Biotechnology 8
 Types of baker’s yeast
Instant yeast
• It has smaller granules with substantially higher percentages of
live cells per comparable unit volumes.
• It is more perishable than active dry yeast
• It also does not require rehydration.
• Instant yeast has a small amount of ascorbic acid added as a preservative.
Compressed yeast
• It is the cream yeast with most of the liquid removed.
http://www.thekitchn.com/whats-the-difference-between-active-dry-yeast-and-instant-yeast-54252
• It is a soft solid, beige in color, and best known in the consumer form
as small, foil-wrapped cubes of cake yeast.
• It is also available in larger-block form for bulk usage.
• It is more tolerant of low temperatures

https://fabko.com/dairy-bakery/3636-fresh-compressed-yeast.html

Prof. Debabrata Das

Department of Biotechnology 9
Production of Baker’s yeast

Prof. Debabrata Das

Department of Biotechnology 10
 Raw materials
• Maltose (costly)
• Starch and cellulose (cheaper alternates)
e.g. rice, maize, wheat, barley, potato and saw dust
• Pretreatment is essential to aid the release of sugars for both
starchy materials and cellulose.
• Enzymatic hydrolysis (Amylase) and acid hydrolysis ( by HCl,
H2S04 ) are used to pre-treat starch
• Cellulose is predominantly pre-treated by acids as it undergoes
complete hydrolysis with concentrated HCl at room temp or
with dilute HCl at higher temperature and pressure.
• Molasses (by product in (1) cane sugar, (2) beet sugar
producing industry) is the most widely raw material.

Prof. Debabrata Das

Department of Biotechnology 11
 Raw materials
Molasses not only supplies N, P, etc. but also some vitamins such as Inositol, Biotin, Pantothinic
acid
• The absence of biotin results in enhancement of lag-period of the fermentation
• In absence of In absence of Inositol, organism relax to ferment sugar.
• In absence of Pantothionate, organism undergo autolysis which is undesirable.
autolysis
Sulpho protein Sulfides.
• By using the judicial mixture of the cone and beet molasses, a balance composition of medium
can be prepared.
• Yeast cells cannot grow without the above vitamins. This is called ‘Bios’.

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Department of Biotechnology 12
 Yeast growth
• Concentration of sugar is 0.5 – 1.5%
• If the medium contains excess of sugar then certain unutilized sugar breaks down to the
alcohol
• This excess sugar is known as exponentially fed assimilation.

• pH-range - 3.5-4.5

• By using (NH4)2 S04 and NH4OH buffer, nitrogen supplementation is done

• Lactic acid bacteria are used in yeast fermentation to prevent contamination esp. putrefying
bacteria.
• Lactic acid is used before the inoculation of other organism
• Optimum temperature 25o –30oC

Prof. Debabrata Das

Department of Biotechnology 13
 Yeast growth requirements
Aeration
Air should be supplied in optimum amount. It helps in -
• Respiration
• Prevent alcohol fermentation
• Growth
• Agitation of the medium
• Removal of toxic products (e.g. CO2)
Surface area of the bubble should be large because it contains large volume of air than the smaller.
Optimum rate of aeration is 1 volume / volume of medium / min.

Foaming
• To control foaming, antifoaming compounds such as octadecanol, tetradecanol, hexadecanol are
added to avoid foam

Prof. Debabrata Das

Department of Biotechnology 14
 Stages of Baker’s yeast preparation
The different stages of Bakers’ yeast preparation are :
• Selection of organism
• Selection of medium for development of seed yeast and
fermentation.
• Fermentation process
• Separation of yeast cells
• Dewatering of yeast
• Packaging
• Distribution under refrigeration of Baker’s yeast

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Department of Biotechnology 15
Block flow diagram of Baker’s yeast production
Molasses

Seed Inoculum Production

culture vessel (IV) Fermenter Filter
(PF) Cooler
press

Binder

Mixer &
Storage at Compressed Packaging Extruder
3-5 oC yeast

Active dry yeast Packaging Dryer

Cold storage

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Department of Biotechnology 16
Design of the medium composition

Prof. Debabrata Das

Department of Biotechnology
Additional materials require in cane molasses for the Baker’s yeast fermentation

Materials requirement with cane molasses:

N – about 1.6-1.8% of nitrogen on molasses weight.

P2O5 - 0.6 – 0.8% on molasses weight

MgO - 0.1 – 0.15% on molasses weight

Prof. Debabrata Das

Department of Biotechnology
Typical materials requirement

For preparation of 1 kg of dry yeast requires :

4.3 kg – molasses
0.9 kg – NH3
0.3 kg – (NH4)H2PO4
1.10 kg – (NH4)2SO4
60 kg of air

Prof. Debabrata Das

Department of Biotechnology
Substrate
(sugar) Biomass
(yeast)

Prof. Debabrata Das

Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology
 Stages of Bakers’ yeast preparation
Development of seed culture
• Proper mixture of beet molasses and cane (60:40) molasses is the best
nutrient for the development of yeast cells.
• In the slant culture, the yeast cell losses the fermentation power, i.e. the
cells undergo lysis because it passes different stages of growth.
• Time factor i.e., log phase is the most important for the growth and
multiplication of yeast cells.
• A laboratory slant culture of age 24 h is used.
• Molasses are must added to the medium in a regular interval of time
• Seed culture is done in 12 h.

Prof. Debabrata Das

Department of Biotechnology
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 Stages of Bakers’ yeast preparation

• Medium is taken through the manhole in the fermenter.

• Steam is passed for sterilizing the medium.
• Seed culture is added.
• Temperature of the medium is controlled at 24-30 oC.
• This fermentation is done in batch process for 12 h.
• In certain interval of time, wort molasses and N, P and MgO is
added in requisite amount.
• Sterile air is added uniformly so that the medium remains in
contact with oxygen.
• The lysis of yeast cells occur due to agitation of the medium, so
agitation is prohibited.
• Antifoaming compounds are added as necessity.

Prof. Debabrata Das

Department of Biotechnology
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 Stages of Bakers’ yeast preparation

Materials of construction of Fermenter & Seed tank

• Stainless steel containers are used.

• It should contain 12 % Cr. It prevents surface corrosion of the tank by

acid.

• It should contain 8 % Ni which gives austenitic structure.

• Contains 2-5 % Mo, which can increases the resistance power of steel by
acid because in fermentation process acids are usually formed.

Prof. Debabrata Das

Department of Biotechnology
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 Recovery of Bakers’ yeast

Separation of yeast cells from fermentation liquor

• Fermentation broth is centrifuged
• It is washed with water to free the cells from coloring matters.
• Ethyl alcohol, propyl alcohol, and butyl alcohol can be used to wash yeast
cell.
• After separation of yeast cell the solution of yeast is called yeast cream, as
it contains water.

Prof. Debabrata Das

Department of Biotechnology
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 http://redstaryeast.com/science-yeast/types-of-yeast/nutritional-yeast/

Prof. Debabrata Das

Department of Biotechnology
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 Recovery of Bakers’ yeast
Preparation Of Compressed & Active Dry Yeast
• Plate-frame filter press is generally use to filter the yeast cells. The yeast cells
which are obtained by filtration called compressed yeasts .

http://www.hofflandenv.com/filter-press/
https://www.andritz.com/products-and-services/pf-detail.htm?productid=5439

Prof. Debabrata Das

Department of Biotechnology
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 Recovery of Bakers’ yeast
Two types of yeast are prepared
• Compressed yeast (27-30 %w/w solid matter).
• Active dry yeast (6-8 %w/w moisture)

Compressed yeast
• Compressed yeast can be spoiled at a room temperature
due to high moisture content.
• Hence, stored in refrigerator.
Active dry yeast
• It does not require refrigeration and phosphorization.
• Before drying, pasteurization is essential. Active dry yeast
are packaged in an atmosphere of N2 or inert atmosphere.
Prof. Debabrata Das
Department of Biotechnology
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 Recovery of Bakers’ yeast
Preparation of active yeast
• The compressed yeast are mixed with plasticizer (e.g. dextrin, pectin, agar)
• It is then passed through the extruder.

• Yeast cake block will be obtained.

• They are cut into blocks and packed in card board.
• Then it is sent to the cold storage room and carefully dried.

http://www.ndhmedical.com/html/extrusion.htm http://www.micronicsinc.com/precision-filtration-products/filter-plates/plate-and-frame-filter-plates/

Prof. Debabrata Das

Department of Biotechnology
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 Contaminants during baker’s yeast production
• Acidic pH is maintained
• Media containing lactic acid is used.

• Acetic acid bacteria and some putrifying bacteria produce (Micrococcus, Flavobacterium, Bacillus)
are the major contaminants.(detected by odor)
• Wild Saccharomyces cereviciae strain has less fermenting power and hence contamination should
be avoided.
• Molds make no problem during yeast fermentation since they are slow growing.

• All the pipes as well as tanks should be properly sterilized. Air pipe contains cotton wool and air is
passed through the pipe to sterilize it.

Prof. Debabrata Das

Department of Biotechnology
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 Quality control and monitoring
The following parameters of the finished product are tested

– Solid Content
– color
– appearance
– dispersion in water
– Nitrogen and phosphors content
– Fermenting power
– package weight
– Baking test

Prof. Debabrata Das

Department of Biotechnology
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 Food yeast
Food yeast
Food yeast”, also known as “nutritional yeast”, is yeast propagated
essentially for food purposes.
It is usually refined and handled under superior conditions.

Food yeast high food value. It should have the following properties-
• High protein content (40-60 %w/w dry yeast)
• Vitamins of the B complex
• It should have acceptable color, and agreeable flavor.
• High growth characteristic in cheaper raw materials
• Easy recoverability.

Prof. Debabrata Das

Department of Biotechnology
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Problem:
One Baker’s Yeast industry produces 1 MT compressed yeast (Saccharomyces cerevisiae) per
day using cane molasses as a raw material in a chemostat. Compresses yeast content 70 % w/w
moisture. The µmax, Ks and Yx/s values of the year are 0.5 h-1, 2 g/L and 0.5 g/g respectively.
Cane molasses contains 45 % (w/w) of sucrose. Initial substrate concentration of the
fermentation broth is 200 g/L. Compute the followings:

a. Minimum doubling time of the cell

b. Total amount of cane molasses required;
c. Volume of the fermenter
d. Maximum cell mass productivity
Solution:
Basis: 1 MT compressed yeast per day ≡ 1000 kg compressed yeast per day
(70 %w/w moister)
=1000 (1- 0.7)= 300 kg day yeast per day

Prof. Debabrata Das

Department of Biotechnology
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Prof. Debabrata Das

Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology
 Prof. Debabrata Das
Department of Biotechnology