Simultaneous Saccharification and Fermentation of Whey Permeate

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Solution Overview

Problem

Current ethanol production from cheese whey using Kluyveromyces sp. is limited by ethanol sensitivity, resulting in low substrate concentrations and yields, while alternative processes with Saccharomyces cerevisiae require high beta-galactosidase concentrations and simultaneous saccharification and fermentation (SSF) at specific pH levels, which are not optimal for high ethanol yields.

Innovation Solution

A process that simultaneously saccharifies lactose-containing substrates using a lactase enzyme and ferments the resulting monosaccharides with Saccharomyces sp. at a pH between 3.5-5.5, optimizing the ratio of hydrolysis time to total fermentation time to achieve an ethanol yield of at least 70% of the theoretical yield, utilizing a lactase enzyme from Bifidobacterium bifidum or Aspergillus oryzae to control lactose conversion and ensure optimal glucose and galactose availability for the yeast.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If Kluyveromyces sp. is used for direct lactose fermentation, then the process can ferment lactose directly to ethanol, but the ethanol yield is limited due to ethanol sensitivity of the yeast

Engineering Contradiction:

Improvedirect lactose fermentation capabilityVSAvoidethanol yield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The fermentation process is segmented into two distinct functional components: (1) lactose hydrolysis by beta-galactosidase enzyme to produce glucose and galactose, and (2) ethanol fermentation by Saccharomyces cerevisiae on the produced monosaccharides. This segmentation allows each component to operate at its optimal performance level, resolving the contradiction between direct fermentation capability and ethanol yield.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Beta-galactosidase enzyme acts as an intermediary that converts lactose into fermentable monosaccharides (glucose and galactose), which then serve as substrates for Saccharomyces cerevisiae. This intermediary mechanism enables the use of high-performance ethanol-producing yeast while overcoming its inability to directly ferment lactose, thereby achieving high ethanol yields.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If Saccharomyces cerevisiae is used with beta-galactosidase for SSF, then high ethanol yields can be achieved, but the process requires specific pH conditions (4.0-5.0) that are not optimal for enzyme activity

Engineering Contradiction:

Improveethanol yieldVSAvoidpH condition flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The process optimizes the pH parameter to a specific range (4.0-5.0) that simultaneously satisfies the requirements of both beta-galactosidase enzyme activity and Saccharomyces cerevisiae fermentation performance. This parameter optimization resolves the contradiction by finding the optimal operating point where both the enzyme-catalyzed hydrolysis and microbial fermentation operate efficiently.

Inventive Principle:

Principle #35Parameter changes

3Speed

If high beta-galactosidase concentration is used for rapid lactose conversion, then hydrolysis is completed quickly, but the cost and process complexity increase

Engineering Contradiction:

Improvelactose hydrolysis rateVSAvoidenzyme concentration control

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

Beta-galactosidase is added to the system before Saccharomyces cerevisiae to pre-hydrolyze lactose into glucose and galactose. This preliminary action ensures that when the yeast is introduced, fermentable substrates are already available, enabling immediate fermentation and achieving high ethanol yields without requiring excessively high enzyme concentrations throughout the entire process.

Inventive Principle:

Principle #10Preliminary action

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 process enhances ethanol yield by carefully controlling lactase activity and fermentation conditions, allowing for efficient conversion of lactose to ethanol, overcoming the limitations of previous methods by achieving higher ethanol production from lactose-containing substrates like whey permeate.

Implementation Method 1

saccharification is carried out in the presence of a lactase

Methodology Applied

Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

using a lactase enzyme from Bifidobacterium bifidum or Aspergillus oryzae to control lactose conversion

Methodology Applied

Scientific EffectEnzyme catalysis: Enzyme

Implementation Method 3

fermenting the monosaccharide to produce ethanol

Methodology Applied

Scientific EffectFermentation: Fermentation

Data Source

PatentUS10696987B2Process for simultaneous saccharfication and fermentation of whey permeate

Publication Date: 2020.06.30 NOVOZYMES AS

AI summary

A process for producing ethanol from lactose containing substrates, comprising simultaneously saccharifying the substrate to produce monosaccharide and fermenting the monosaccharide to produce ethanol at a pH from 3.5-5.5, using a fermenting organism, wherein saccharification is carried out in the presence of a lactase, and wherein the fermenting organism is a Saccharomyces sp., and the ratio between the incubation time required for obtaining at least 90% hydrolysis of the lactose present in the substrate (t1) and the total fermentation time (t2) is in the range of 0.1 to 1, and the Saccharomyces sp. is added in amounts that will result in an ethanol yield of at least 70% w/w of the theoretical ethanol yield from lactose by the end of fermentation.