Enzymatic Fermentation of Starch Feedstocks for Higher Ethanol Yield

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Solution Overview

Problem

The production of fermentation products from starch-containing materials is costly due to low yield, necessitating improved processes to enhance productivity and reduce costs.

Innovation Solution

The use of a cellulolytic composition derived from Trichoderma reesei, Humicola insolens, or Chrysosporium lucknowense, comprising beta-glucosidase, cellobiohydrolase, and endoglucanase, along with optional hemicellulases, to liquefy, saccharify, and ferment starch-containing materials, combined with glucoamylase and trehalase for enhanced ethanol recovery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional fermentation processes are used to produce ethanol from starch-containing materials, then the production process is simple and well-established, but the ethanol yield is low and production costs are high

Engineering Contradiction:

Improveethanol yieldVSAvoidproduction cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent combines multiple enzyme functions into a single consolidated saccharification step. Specifically, it merges the functions of alpha-amylase (for starch liquefaction), glucoamylase (for glucose production), and cellulolytic enzymes (for cellulosic material degradation) into an integrated enzymatic treatment process, thereby improving ethanol yield while maintaining process simplicity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention employs a multi-functional enzymatic system where a single enzyme preparation contains multiple types of enzymes (amylases, glucoamylases, cellulases, hemicellulases) that can simultaneously or sequentially act on different components of the substrate (starch, cellulose, hemicellulose). This universal enzyme cocktail enables the process to handle both starch and cellulosic materials effectively, increasing overall ethanol yield from mixed substrates

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If starch-containing materials are used as substrate, then the fermentation process is well-established, but the ethanol yield per unit substrate is insufficient to reduce production costs

Engineering Contradiction:

Improveethanol yield per substrateVSAvoidsubstrate utilization efficiency

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent segments the substrate utilization process into distinct enzymatic stages: (1) alpha-amylase for initial starch liquefaction, (2) glucoamylase for complete starch saccharification to glucose, and (3) cellulolytic enzymes for concurrent cellulosic material degradation. This segmentation allows each enzyme to optimally process its specific substrate component, maximizing overall substrate utilization efficiency and ethanol yield

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention applies preliminary enzymatic treatment to the substrate before fermentation by pre-saccharifying starch and cellulosic materials using the multi-enzyme system. This preliminary action converts complex polymers into fermentable sugars in advance, ensuring maximum sugar availability for the fermenting organism and thereby improving ethanol yield per unit substrate

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If whole stillage is produced after fermentation, then the fermentation process is complete, but the dewatering and separation of fermentation products becomes difficult and costly

Engineering Contradiction:

Improveseparation efficiencyVSAvoiddewatering efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent introduces an intermediary enzymatic treatment step using cellulolytic enzymes that modify the physical structure of cellulosic materials in the stillage. This intermediary action degrades cellulose into smaller fragments and soluble products, which acts as a mediator to improve the dewatering characteristics of whole stillage, facilitating easier separation of fermentation products while maintaining production efficiency

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly increases ethanol yield and improves the dewatering of whole stillage, reducing production costs and optimizing the separation of fermentation products.

Implementation Method 1

The cellulolytic composition comprises a beta-glucosidase, a cellobiohydrolase, and an endoglucanase

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

fermenting using a fermentation organism

Methodology Applied

Scientific EffectFermentation: Fermentation

Implementation Method 3

liquefying a starch-containing material with an alpha-amylase

Methodology Applied

Scientific EffectEnzyme hydrolysis: Hydrolysis

Data Source

PatentUS12540340B2Processes of producing fermentation products

Publication Date: 2026.02.03 NOVOZYMES AS

AI summary

The invention relates to processes of producing a fermentation product, comprising liquefying a starch containing material with an alpha-amylase; pre-saccharifying and/or saccharifying and fermenting using a fermentation organism in the presence of a carbohydrate source generating enzyme and a cellulolytic composition The invention also relates to methods of dewatering whole stillage.