VISIT TO AB MAURI

FOODS, LAHORE
SUBMITTED BY: RAZMIA SABAHAT
BUTT
239424, UG-10
SUBMITTED TO: DR. TAHIR A. BAIG
FERMENTATION
BIOTECHNOLOGY
FAB-368
ATTA-UR-RAHMAN
SCHOOL OF APPLIED
BIOSCIENCES
Introduction:
Located in the capital of Punjab, AB Mauri is the only industry involved in the Yeast Production
all around Pakistan. This industry is equipped with facilities involving:
 Yeast Production
 Fermentation
 Laboratories to check the performance level of different types of yeast
 Bakery
 RO plant which treats the waste water before it can be dumped into the water reservoirs
or used in Cooling Towers within the Industry
AB Mauri is specialized for the production of Baker’s Yeast which is further used by other
industries for the manufacturing of bakery product mainly Bread.
The types of yeast being produced by AB Mauri are as follows:
1. Cream Yeast
2. Compressed Yeast
3. Dry or Powdered Yeast
Manufacturing Process:
The production of Baker’s Yeast involves the following five steps:
1. Preparation of Raw Materials
2. Production of Seed Yeast
3. Fermentation
4. Separation
5. Storage and Packaging

Step 1: Preparation of the Raw Material

The pure culture of yeast named as Inoculum is prepared at the AB Mauri Foods, Research and
Development Centre at North Ryde, Sydney. The inoculum is then distributed to the
manufacturing centers all around the globe. This inoculum which is required for the production
of yeast is grown on nutrients and maintained under frozen conditions.
Molasses are the remains of sugar cane obtained after the extraction of sugarcane juice. They
also serve as the raw material for the production of yeast as they contain a large amount of sugar
content that can be used by the yeast as carbon source. Yeast in the inoculum utilizes sugar in the
molasses as food and increases its growth and population. However, before putting molasses and
other raw material into the fermenter, the molasses are sterilized or washed by dipping them in
Bleach or in Chlorinated water.
The raw materials used in the production of yeast/fermentation are as follows:
 Sodium Benzoate
 Soda ash
  Magnesium sulfate
 Bleach
 Caustic soda
 Salt
 Vitamins
 Phosphoric Acid
 Cooking oils
 Antifoam
All of the above raw materials are mixed before they can be put into the main fermenter.

Step 2: Production of Seed Yeast

This step involves the bleaching/washing of the Molasses to get rid of unwanted microbes. All
the above mentioned raw materials are mixed in the required ratio and the mixture is then put
into the Seed Fermenter (Main Fermenter involved in the production)

Step 3: Fermentation
Once the yeast is provided with the required raw materials, it is allowed to increase its growth
and population. The yeast cells utilize the sugars from molasses, vitamins and salts from the
added raw material and begins its growth, giving rise to the daughter yeast cells.
AB Mauri is equipped with 5 main fermenters of 250KG each, in order to divide the total load.
The total time taken by the fermentation process is approximately 10minutes. The fermentation
process is carried out in Batches and the amount of product obtained after one batch is about
12000Kg. Aerobic Fermentation is carried out and the aeration is provided through High Speed
Blowers to allow the circulation of the materials.

Step 4: Separation
When the required amount of yeast is produced in the fermenter, the yeast cells and the other
materials are separated through High Speed Centrifugation. The effluent obtained as a result of
separation goes into the effluent treatment plant.
The main aim of AB Mauri Foods is 0% discharge, meaning that the pollutants or effluent
discharge into the environment is minimized to zero. In order to achieve this, the effluent is
further refined into the Sludge and Raw Water. The water passes through many filtration
processes and is utilized within the Cooling Towers in order to cool down the machinery.
The effluent obtained after the fermentation process is handed over to Auriga Group of
Companies which utilizes the effluent for the production of Biofuels.

Step 5: Packaging and Storage

In order to maintain the stability and activity of the Yeast, it is stored in steel tanks at low
temperature. As the main manufacturing process involves the production of Cream Yeast, it can
be further processed to produce Compressed or Dry Yeast.
For the production of Compressed Yeast, the cream yeast is fed into the Continuous Rotary
Vacuum Filters, where extra water is removed from the cream yeast. After this, the yeast is
compressed into blocks, cut through knives into the blocks of same size, packaged and stored.
For the production of Dry/Powdered Yeast, the cream yeast is fed into vacuum filters, the
yeast is dewatered and then fed into the Drying Tower, where the yeast is dried to small granules
of high activity. This powdered yeast is packaged and transported to the market.
Summary:
The following Flowchart gives the main idea of the manufacturing process

Molasses, Raw Materials

and Yeast Cells (Inoculum)
are mixed

Fermentation for 10-15

minutes. The yeast cells
divide and grow during this.

Separation of Yeast Cells

and Effluent

Cream Yeast Effluent

Vacuum
Filters
Raw Water Sludge

RO
Compressed Drying
Treatment
to Blocks Tower

Used in Cooling
Compressed Dried/Powdered
Tower
Yeast Yeast

Packaging and Storage