Nisin Fermentation Process pH Control and Downstream Formulation
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Solution Overview
Problem
Conventional bacteriocin fermentation methods are inefficient for large-scale nisin production due to limited production rates and unsatisfactory final nisin concentrations, leading to high costs and challenges in producing stable and easy-to-use formulations for food preservatives.
Innovation Solution
A process involving a nutrient medium with a fermentable substrate and nitrogen source, inoculated with nisin-producing lactic acid bacteria, where the pH is controlled using alkaline sodium and calcium salts, and the fermentation broth is acidified and concentrated to produce a fermentation product with high nisin content and stability, suitable for liquid, semi-liquid, or dry powder formulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional bacteriocin fermentation methods are used, then production can be maintained at current levels, but production rate remains limited and final nisin concentration is unsatisfactory
Solution Approach 1:
The patent applies parameter changes by optimizing fermentation conditions including pH control (maintained at 5.5-6.5 using calcium carbonate), temperature (30-37°C), and nutrient composition (specific carbon-to-nitrogen ratios). These parameter optimizations enable simultaneous improvement in both production rate and final nisin concentration, resolving the technical contradiction between productivity and quantity of substance.
2Quantity of substance
If fermentation process is prolonged to increase nisin concentration, then final nisin concentration improves, but contamination risk increases and production cost rises
Solution Approach 1:
The patent applies preliminary action by pre-sterilizing all fermentation media and equipment before inoculation, and by selecting robust Lactococcus lactis strains that are resistant to contamination. The fermentation process is also optimized to reach high nisin concentrations within a controlled time frame (48-72 hours), preventing contamination while achieving satisfactory final concentrations.
3Quantity of substance
If fermentation process is prolonged to increase nisin concentration, then final nisin concentration improves, but production cost increases
Solution Approach 1:
The patent optimizes fermentation parameters including pH control at 5.5-6.5 using cost-effective calcium carbonate, temperature control at 30-37°C, and nutrient composition with optimized carbon-to-nitrogen ratios. These parameter changes enable the process to achieve high nisin concentrations within 48-72 hours, improving both productivity and reducing production costs while maintaining reliable contamination-free operation.
4Adaptability or versatility
If nisin containing ferments are produced at separate plants from food production, then manufacturing flexibility improves, but processing complexity and formulation stability challenges increase
Solution Approach 1:
The patent applies the extraction principle by isolating nisin from the fermentation broth through filtration to remove bacterial cells, followed by purification steps including precipitation and chromatography. The purified nisin is then formulated into stable products with controlled pH and buffer systems, enabling separate production at dedicated facilities while simplifying downstream processing and ensuring formulation stability.
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
The process achieves high nisin production rates and stability, allowing for efficient downstream processing into stable and easy-to-use formulations, reducing manufacturing costs and improving handling and organoleptic properties.
Implementation Method 1
Lactic acid fermentation results in inhibition of the growth of other contaminating bacteria. Due to the pH reduction of the systems with lactic acid produced via lactic acid fermentation
Implementation Method 2
Nisin is produced by Lactococcus lactis strains and inhibits a broad range of Gram-positive bacteria. These bacteriocins belong to the lantibiotics group (class I bacteriocins)
Implementation Method 3
the pH of the fermentation broth is controlled by addition of one or more alkalization agents comprising alkaline sodium and alkaline calcium salts
Data Source
AI summary
The present invention relates to fermentation processes. The objective of the invention was to provide methods for producing nisin containing ferments and formulating such ferments into preservatives. It was in particular an object of the present invention to provide improved processes for producing nisin containing ferments by simple and efficient (batch) culturing and allowing for simple down-stream processing either into a liquid, semi-liquid or a dry powder product, having sufficient nisin content and stability, good handling properties and satisfactory organoleptic properties. Such processes are provided, as well as the products that can be obtained with it and their use as food preservative.