Whey valorisation: a complete and novel technology development for dairy industry starter culture production

Assessment of the antifungal efficacy of whey fermentate alone or in combination with citrus extract to control Aspergillus flavus mold in semi-moist pet food for dogs

Semi-moist pet foods contain moisture levels ranging from 15 to 40%, making them ideal for mold growth and mycotoxin production. To control spoilage, synthetic mold inhibitors such as potassium sorbate have been used, but consumers prefer "natural" preservatives. Whey fermentate (WPF) is an efficient antifungal, but it requires large doses. Therefore, the objective of this study was to determine the antifungal effect of WPF alone or in combination with citrus extract oil (CEX) against Aspergillus flavus in semi-moist pet food. Nutritionally complete semi-moist pet foods were produced with WPF alone [0.25, 0.5, and 1.0% (w/w)] and in combination with CEX; 0.25% WPF+ 0.015% CEX, 0.25% WFP+ 0.15% CEX, 0.5% WPF+ 0.015% CEX, and 0.5% WFP+ 0.15% CEX (w/w). The negative control (NC) contained no antifungal additive and the positive control (PC) had potassium sorbate (0.1% w/w). The semi-moist pet food was thermally formed and was cut into 3 cm × 3 cm square pieces. Individual food pieces were inoculated with 0.1 mL of Aspergillus flavus (ATCC 204304) to achieve a final concentration of ~5.0 log CFU/piece. The inoculated pieces were individually incubated at 25°C. Fungal analysis was performed on day 3, 6, 9, 12, 15, 18, 21, 24, and 28 by surface plating on Potato Dextrose Agar (PDA) followed by incubation at 25°C for 72 h. The total log reductions were calculated by subtracting the initial inoculum from the final log counts on day 28. Higher log reductions of Aspergillus flavus (p < 0.05) were observed when WPF at 0.25 and 0.5% was combined with 0.15% CEX compared to when 0.015% CEX was used individually. All treatments were different from the NC (p < 0.05). Citrus extract at 0.15% potentiated the antifungal effect of WPF at 0.5% to give a similar log reduction (p > 0.05) to WPF at 1.0% in the food. In conclusion, CEX potentiated the antifungal efficacy and reduced the dose of WPF required to control Aspergillus flavus in semi-moist dog food.

Sources and methods of manufacturing xanthan by fermentation of various carbon sources

Xanthan gum, an anionic polysaccharide with an exceptionally high molecular weight, is produced by the bacterium Xanthomonas sp. It is a versatile compound that has been utilized in various industries for decades. Xanthan gum was the second exopolysaccharide to be commercially produced, following dextran. In 1969, the US Food and Drug Administration (FDA) approved xanthan gum for use in the food and pharmaceutical industries. The food industry values xanthan gum for its exceptional rheological properties, which make it a popular thickening agent in many products. Meanwhile, the cosmetics industry capitalizes on xanthan gum's ability to form stable emulsions. The industrial production process of xanthan gum involves fermenting Xanthomonas in a medium that contains glucose, sucrose, starch, etc. as a substrate and other necessary nutrients to facilitate growth. This is achieved through batch fermentation under optimal conditions. However, the increasing costs of glucose in recent years have made the production of xanthan economically unviable. Therefore, many researchers have investigated alternative, cost-effective substrates for xanthan production, using various modified and unmodified raw materials. The objective of this analysis is to investigate how utilizing different raw materials can improve the cost-efficient production of xanthan gum.

Soybean fermentation: Microbial ecology and starter culture technology

Fermented soybean products, including Soya sauce, Tempeh, Miso, and Natto have been consumed for decades, mainly in Asian countries. Beans are processed using either solid-state fermentation, submerged fermentation, or a sequential of both methods. Traditional ways are still used to conduct the fermentation processes, which, depending on the fermented products, might take a few days or even years to complete. Diverse microorganisms were detected during fermentation in various processes with Bacillus species or filamentous fungi being the two main dominant functional groups. Microbial activities were essential to increase the bean's digestibility, nutritional value, and sensory quality, as well as lower its antinutritive factors. The scientific understanding of fermentation microbial communities, their enzymes, and their metabolic activities, however, still requires further development. The use of a starter culture is crucial, to control the fermentation process and ensure product consistency. A broad understanding of the spontaneous fermentation ecology, biochemistry, and the current starter culture technology is essential to facilitate further improvement and meet the needs of the current extending and sustainable economy. This review covers what is currently known about these aspects and reveals the limited available information, along with the possible directions for future starter culture design in soybean fermentation.

Opportunities and challenges of machine learning in bioprocesses: Categorization from different perspectives and future direction

Recent advances in machine learning (ML) have revolutionized an extensive range of research and industry fields by successfully addressing intricate problems that cannot be resolved with conventional approaches. However, low interpretability and incompatibility make it challenging to apply ML to complicated bioprocesses, which rely on the delicate metabolic interplay among living cells. This overview attempts to delineate ML applications to bioprocess from different perspectives, and their inherent limitations (i.e., uncertainties in prediction) were then discussed with unique attempts to supplement the ML models. A clear classification can be made depending on the purpose of the ML (supervised vs unsupervised) per application, as well as on their system boundaries (engineered vs natural). Although a limited number of hybrid approaches with meaningful outcomes (e.g., improved accuracy) are available, there is still a need to further enhance the interpretability, compatibility, and user-friendliness of ML models.

Identification, characterization and in vitro activity of hypoglycemic peptides in whey hydrolysates from rubing cheese by-product

The by-product of Chinese rubing cheese is rich in whey protein. Whey hydrolysates exhibit good hypoglycemic activity, but which specific peptide components are responsible for this effect have not yet been investigated. Herein, the α-glucosidase inhibitory activity of the ultrafiltered fraction (<3 kDa) of rubing cheese whey hydrolysates was evaluated with the inhibition rate of 37.89 %. In addition, peptide identification was conducted using LC-MS/MS, and three peptides YPVEPF, VPYPQ, and LPYPY were identified. Among these, YPVEPF had higher α-glucosidase inhibitory activity (IC₅₀ = 3.52 mg/mL) and interacted with α-glucosidase via hydrogen bonding and hydrophobic forces. YPVEPF was characterized as an amphipathic peptide rich in antiparallel (50.50 %) and random coil (35.20 %) structures, as well as showed good tolerance to gastrointestinal digestion and incubation under the temperature range of 20-80 °C. Notably, YPVEPF activity increased in the presence of Al³⁺ and Fe³⁺, as well as within the pH range of 2.0-6.0. Furthermore, YPVEPF had negligible hemolytic activity at a concentration of 1.0 mg/mL, no toxicity at concentrations below 0.5 mg/mL, and significantly promoted glucose consumption in HepG2 cells (p < 0.0001). Collectively, these findings indicate the potential of YPVEPF to be used as a novel hypoglycemic peptide in functional foods.

Characterization of major volatile compounds in whey spirits produced by different distillation stages of fermented lactose-supplemented whey

This research aimed to advance the understanding of acceptable sensory qualities of potable whey-based spirit from nonsupplemented, mid-supplemented, and high-supplemented whey samples by analyzing major volatile compounds during different stages of distillation (head, heart, and tail). The results demonstrated that commercial Saccharomyces cerevisiae strain in lactase-hydrolyzed whey showed rapid and complete sugar hydrolysis and efficient ethanol production in 24, 30, and 36 h on average, producing up to 29.5, 42.1, and 56.4 g/L of ethanol, respectively. The variations in titratable acidity, specific gravity, pH value, residual protein, sugar content, and alcohol yield were investigated during the fermentation. The total amount of volatile compound concentrations significantly decreased from the head (2,087-2,549 mg/L) to the tail whey spirits (890-1,407 mg/L). In the whey spirit, 2-methyl-1-butanol, 3-methyl-1-butanol, 2-methyl-1-propanol, 1-propanol, acetaldehyde, and ethyl acetate were the most prevalent ruling compounds, accounting for the largest proportion of total volatile compounds. The volatile compounds detected were far below the acceptable legal limit. The results suggest that high sensory qualities of potable whey-based spirits can be produced by fermentation of lactose-supplemented whey with S. cerevisiae cells.

Kefir as a Functional Beverage Gaining Momentum towards Its Health Promoting Attributes

The consumption of fermented foods posing health-promoting attributes is a rising global trend. In this manner, fermented dairy products represent a significant subcategory of functional foods with established positive health benefits. Likewise, kefir—a fermented milk product manufactured from kefir grains—has been reported by many studies to be a probiotic drink with great potential in health promotion. Existing research data link regular kefir consumption with a wide range of health-promoting attributes, and more recent findings support the link between kefir’s probiotic strains and its bio-functional metabolites in the enhancement of the immune system, providing significant antiviral effects. Although it has been consumed for thousands of years, kefir has recently gained popularity in relation to novel biotechnological applications, with different fermentation substrates being tested as non-dairy functional beverages. The present review focuses on the microbiological composition of kefir and highlights novel applications associated with its fermentation capacity. Future prospects relating to kefir’s capacity for disease prevention are also addressed and discussed.

Signatures of optimal codon usage in metabolic genes inform budding yeast ecology

Reverse ecology is the inference of ecological information from patterns of genomic variation. One rich, heretofore underutilized, source of ecologically relevant genomic information is codon optimality or adaptation. Bias toward codons that match the tRNA pool is robustly associated with high gene expression in diverse organisms, suggesting that codon optimization could be used in a reverse ecology framework to identify highly expressed, ecologically relevant genes. To test this hypothesis, we examined the relationship between optimal codon usage in the classic galactose metabolism (GAL) pathway and known ecological niches for 329 species of budding yeasts, a diverse subphylum of fungi. We find that optimal codon usage in the GAL pathway is positively correlated with quantitative growth on galactose, suggesting that GAL codon optimization reflects increased capacity to grow on galactose. Optimal codon usage in the GAL pathway is also positively correlated with human-associated ecological niches in yeasts of the CUG-Ser1 clade and with dairy-associated ecological niches in the family Saccharomycetaceae. For example, optimal codon usage of GAL genes is greater than 85% of all genes in the genome of the major human pathogen Candida albicans (CUG-Ser1 clade) and greater than 75% of genes in the genome of the dairy yeast Kluyveromyces lactis (family Saccharomycetaceae). We further find a correlation between optimization in the GALactose pathway genes and several genes associated with nutrient sensing and metabolism. This work suggests that codon optimization harbors information about the metabolic ecology of microbial eukaryotes. This information may be particularly useful for studying fungal dark matter-species that have yet to be cultured in the lab or have only been identified by genomic material.

Solid inoculants as a practice for bioaugmentation to enhance bioremediation of hydrocarbon contaminated areas

Vacuum freeze-drying is a scientifically advanced method to prepare solid inoculants from oil degrading bacterium. The introduction of oil-degrading microbes or bioaugmentation can be an efficient way to bioremediate oil spills in marine areas, where oil-degrading bacteria are deficient. The purpose of this study is to evaluate the potential use of solid inoculants of LZ-2 bacteria to enhance the degradation rate of crude oil. In this study, response surface methodology (RSM) was incorporated into the experimental design to optimize a response, which is influenced by different protectants. Our results showed that five factors have interactive and synergistic protective effects on the growth of LZ-2. Optimal growth of freeze-dried LZ-2 (63.8%) was observed with a 10.5% solution of skim milk supplemented with 14.3% sucrose, 14.4% of trehalose, 4.9% of glycerin and 14.7% of β-cyclodextrin. The culture grew in medium containing crude oil (3 g L^-1) at 37 °C at 150 rpm for 30 d, GC and GC-MS analysis showed biodegradation of 44.2 and 21.6% for total saturate and aromatic hydrocarbons respectively. These results indicated that the solid inoculants of LZ-2 bacteria had the potential to be used for ex-situ bioremediation of hydrocarbon pollutants associated with crude oil.

Invited review: Acid whey trends and health benefits

In recent years, acid whey production has increased due to a growing demand for Greek yogurt and acid-coagulated cheeses. Acid whey is a dairy by-product for which the industry has long struggled to find a sustainable application. Bulk amounts of acid whey associated with the dairy industry have led to increasing research on ways to valorize it. Industry players are finding ways to use acid whey on-site with ultrafiltration techniques and biodigesters, to reduce transportation costs and provide energy for the facility. Academia has sought to further investigate practical uses and benefits of this by-product. Although modern research has shown many other possible applications for acid whey, no comprehensive review yet exists about its composition, utilization, and health benefits. In this review, the industrial trends, the applications and uses, and the potential health benefits associated with the consumption of acid whey are discussed. The proximal composition of acid whey is discussed in depth. In addition, the potential applications of acid whey, such as its use as a starting material in the production of fermented beverages, as growth medium for cultivation of lactic acid bacteria in replacement of commercial media, and as a substrate for the isolation of lactose and minerals, are reviewed. Finally, the potential health benefits of the major protein constituents of acid whey, bioactive phospholipids, and organic acids such as lactic acid are described. Acid whey has promising applications related to potential health benefits, ranging from antibacterial effects to cognitive development for babies to human gut health.

Sustainability of food waste biorefinery: A review on valorisation pathways, techno-economic constraints, and environmental assessment

The need to increase circularity of industrial systems to address limited resources availability and climate change has triggered the development of the food waste biorefinery concept. However, for the development of future sustainable industrial processes focused on the valorisation of food waste, critical aspects such as (i) the technical feasibility of the processes at industrial scale, (ii) the analysis of their techno-economic potential, including available quantities of waste, and (iii) a life cycle-based environmental assessment of benefits and burdens need to be considered. The goal of this review is to provide an overview of food waste valorisation pathways and to analyse to which extent these aspects have been considered in the literature. Although a plethora of food waste valorisation pathways exist, they are mainly developed at lab-scale. Further research is necessary to assess upscaled performance, feedstock security, and economic and environmental assessment of food waste valorisation processes.

Kluyveromyces marxianus: An emerging yeast cell factory for applications in food and biotechnology

Several yeasts, which are eukaryotic microorganisms, have long been used in different industries due to their potential applications, both for fermentation and for the production of specific metabolites. Kluyveromyces marxianus is one of the most auspicious nonconventional yeasts, generally isolated from wide-ranging natural habitats such as fermented traditional dairy products, kefir grain, sewage from sugar industries, sisal leaves, and plants. This is a food-grade yeast with various beneficial traits, such as rapid growth rate and thermotolerance that make it appealing for different industrial food and biotechnological applications. K. marxianus is a respiro-fermentative yeast likely to produce energy by either respiration or fermentation pathways. It generates a wide-ranging specific metabolites and could contribute to a variety of different food and biotechnological industries. Although Saccharomyces cerevisiae is the most widely used dominant representative in all aspects, many applications of K. marxianus in biotechnology, food and environment have only started to emerge nowadays; some of the most promising applications are reviewed here. The general physiology of K. marxianus is outlined, and then the different applications are discussed: first, the applications of K. marxianus in biotechnology, and then the recent advances and possible applications in food, feed and environmental industries. Finally, this review provides a discussion of the main challenges and some perspectives for targeted applications of K. marxianus in the modern food technology and applied biotechnology in order to exploit the full potential of this yeast which can be used as a cell factory with great efficiency.

Production of bacterial cellulose from whey-current state and prospects

Bacterial cellulose (BC) is a biopolymer with a wide range of potential applications starting from the food industry and biomedicine to electronics and cosmetics. Despite that, BC industrial production to date still is associated with certain difficulties. One of them is the high cost of growth media, which can reach up to 30% of production costs. To decrease production costs, use of industrial and agricultural by-products, including whey, as alternative growth media has been reported. Whey, as the main high-volume by-product of dairy industry, which is known for its low valorisation opportunities and negative environmental impact, can nevertheless be considered as an alternative growth medium for BC production. To date, several studies aimed at evaluating BC production on whey and lactose substrates have been reported, but they are still insufficient. Reviews of them showed that, in general, BC production on untreated whey- and lactose-containing media was lower than that on the standard medium. However, some wild and recombinant strains have been reported to produce BC on whey as good as the standard medium. Enzymatic and acidic pre-treatment of whey significantly enhanced BC yield. Changes in the microstructure of BC obtained from whey were also recognised, which should be considered regarding the impact on physical properties of the desired BC product. This mini-review indicates that currently whey can be recognised as quite a problematic alternative growth substrate for industrial BC production; however, further extensive studies may improve the prospects in both the search for a cheap alternative growth substrate for industrial BC production and valorisation of whey. KEY POINTS: • Whey is a by-product in which valorisation is still challenging. • Whey can be used for bacterial cellulose (BC) production. • BC yield and properties vary upon cultivation conditions and producer strains.

Whey and molasses as inexpensive raw materials for parallel production of biohydrogen and polyesters via a two-stage bioprocess: New routes towards a circular bioeconomy

Consecutive dark-fermentation and photo-fermentation stages were investigated for a profitable circular bio-economy. H₂ photo-production versus poly(3-hydroxybutyrate) (P3HB) accumulation is a modern biotechnological approach to use agro-food industrial byproducts as no-cost rich-nutrient medium in eco-sustainable biological processes. Whey and molasses are very important byproducts rich in nutrients that lactic acid bacteria can convert, by dark-fermentation, in dark fermented effluents of whey (DFE_W) and molasses (DFE_M). These effluents are proper media for culturing purple non-sulfur bacteria, which are profitable producers of P3HB and H₂. The results of the present study show that Lactobacillus sp. and Rhodopseudomonas sp. S16-VOGS3 are two representative genera for mitigation of environmental impact. The highest productivity of P3HB (4.445 mg/(L·h)) was achieved culturing Rhodopseudomonas sp. S16-VOGS3, when feeding the bacterium with 20% of DFE_M; the highest H₂ production rate of 4.46 mL/(L·h) was achieved when feeding the bacterium with 30% of DFE_M.

Valorization of residual soft drinks by baker's yeast production and insight for dairy wastewater whey incorporation

Residuals are responsible for the polluting load increase of soft drink industry wastewater due to their high sugar contents. The present work proposes an upstream segregation of residuals to be biologically treated by the bioconversion of their carbohydrates content into baker's yeast biomass. Carbonated soft drinks (CSD) and nectars and juices (NJ) ranges were considered. Different incorporation ratios of NJ in the CSD (0-75%) have been investigated for balanced growth medium. Despite the nitrogen deficiency of media, results showed that NJ incorporation promoted the microbial growth. Media containing more than 50% of NJ exhibited ∼25% sugar-biomass conversion rates. The chemical oxygen demand (COD) of the media exceeded 70% at the end of fermentation. Moreover, valuable components were recovered by yeast production. Nutrient consumption rates varied from 65.4% for sugar and calcium content to in excess of 99% for protein and other minerals. In order to investigate an available and low-cost source of nitrogen for yeast production, partial substitution of the soft drink growth medium by bactofugate whey was evaluated. The soft drink-whey mixture medium fermentation resulted in 63% COD removal rate after 28 h. Meanwhile, the biomass production yield revealed an improvement of about 25% compared to the balanced soft drink medium (NJ50).

Multifunctional Role of the Whey Culture Medium in the Spray Drying Microencapsulation of Lactic Acid Bacteria

This study aims to evaluate the multifunctional role of whey culture medium during the spray drying microencapsulation of Lactobacillus fermentum K73. Whey culture medium containing growing microorganisms served to hydrate different mixtures (gum arabic, maltodextrin and whey). We evaluated the use of these mixtures as carbon sources and their protective effects on simulated gastrointestinal conditions. The optimal mixture was spray-dried while varying the outlet temperature and atomizing pressure using a response surface design. These conditions served to evaluate microorganism survival, tolerance to gastrointestinal conditions in vitro, physicochemical properties, morphometric features and stability at 4, 25 and 37 °C. Lactobacillus fermentum K73 replicated in the carrier material. Bacterial change cycles were (-1.97±0.16) log CFU/g after the drying process and 
(-0.61±0.08) and (-0.23±0.00) log CFU/g after exposure of the capsules to simulated gastric pH and bile salt content, respectively. The physicochemical properties and morphometric features were within the normal ranges for a powder product. The powder was stable at a storage temperature of 4 °C. The spray drying of the whey culture medium with growing microorganisms using the optimized drying conditions was successful. This study demonstrates the use of whey culture medium as a component of carrier material or as the carrier material itself, as well as its protective effects during drying, under simulated gastrointestinal conditions, and at varied storage temperatures.

Development and storage studies of high density macrocapsules containing Lactobacillus spp. strains as nutritional supplement in young calves

The aim of this study was to evaluate different production methodologies of probiotic macrocapsules with high bacterial densities destined to lactating calves. Three types of capsules containing Lactobacillus casei DSPV318T and Lactobacillus plantarum DSPV354T were prepared from an overnight culture in whey medium: (1) mixing the culture with calcium alginate and then, reincubating the capsules in whey (RC); (2) concentrating the biomass by centrifugation and mixing the pellet with calcium alginate (CC) at different concentrations with respect to the initial culture (5X and 12.5X); (3) CC with cryoprotectants: whey permeate (Per) and glycerol (Gly). Chitosan coating was evaluated. Capsules were freeze-dried and viability was assessed before freezing, after freeze-drying and every two weeks for 84 days of storage at room temperature, 4°C and -20°C. CC showed higher cell densities than RC. Storage temperature affected viability: greater viability at lower temperature. Moreover, the effect of temperature was influenced by other factors, such as capsule coating, culture neutralization and cryoprotectants. Coating improved viability at room temperature; however no effect was observed at 4°C. Culture neutralization allowed greater survival during storage. Cryoprotectants improved viability during freezing, but they also generated a positive or negative effect depending on storage temperature. The best results were: at refrigeration Gly12.5X exhibited counts above 10⁹CFU/capsule until day 70 and Per12.5X until day 56 of storage and at -20°C Gly12.5X showed counts above 10⁹CFU/capsule until the end of the study (84 days). A 10⁹CFU capsule is the daily dose per calf which would facilitate the administration of this probiotic inoculum to field animals.

Inhibitory substances production by Lactobacillus plantarum ST16Pa cultured in hydrolyzed cheese whey supplemented with soybean flour and their antimicrobial efficiency as biopreservatives on fresh chicken meat

Cheese whey, the main byproduct of the dairy industry, is one of the most worrisome types of industrial waste, not only because of its abundant annual global production but also because it is a notable source of environmental pollution. However, cheese whey can serve as a raw material for the production of biocomposites. In this context, in this study, we assayed the production of a bacteriocin-like inhibitory substance (BLIS) and lactate by culturing Lactobacillus plantarum ST16Pa in hydrolyzed fresh cheese whey. The process was improved by studying the enzymatic hydrolysis of cheese whey as well as its supplementation with soybean flour under microaerophilic or anaerobic conditions. Thus, the highest values of BLIS (7367.23 arbitrary units [AU]/mL) and lactate yield (Ylactate/lactose=1.39g/g) were achieved after addition of 10g/L soybean flour in microaerophilia. These conditions were successfully scaled up in a bioreactor because during complete anaerobiosis at 150rpm, L. plantarum ST16Pa attained considerable cell growth (3.14g/L), lactate concentration (14.33g/L), and BLIS activity (8082.56AU/mL). In addition, the cell-free supernatant resulting from this bioprocess showed high biopreservative efficiency in chicken breast fillets artificially contaminated with Enterococcus faecium 711 during 7days of refrigerated storage, thus indicating the potential use of this BLIS as a biopreservative in the food industry.

Lactose Hydrolysis in Milk and Dairy Whey Using Microbial β-Galactosidases

This work aimed at evaluating the influence of enzyme concentration, temperature, and reaction time in the lactose hydrolysis process in milk, cheese whey, and whey permeate, using two commercial β-galactosidases of microbial origins. We used Aspergillus oryzae (at temperatures of 10 and 55°C) and Kluyveromyces lactis (at temperatures of 10 and 37°C) β-galactosidases, both in 3, 6, and 9 U/mL concentrations. In the temperature of 10°C, the K. lactis β-galactosidase enzyme is more efficient in the milk, cheese whey, and whey permeate lactose hydrolysis when compared to A. oryzae. However, in the enzyme reaction time and concentration conditions evaluated, 100% lactose hydrolysis was not reached using the K. lactis β-galactosidase. The total lactose hydrolysis in whey and permeate was obtained with the A. oryzae enzyme, when using its optimum temperature (55°C), at the end of a 12 h reaction, regardless of the enzyme concentration used. For the lactose present in milk, this result occurred in the concentrations of 6 and 9 U/mL, with the same time and temperature conditions. The studied parameters in the lactose enzymatic hydrolysis are critical for enabling the application of β-galactosidases in the food industry.

Lactic acid fermentation by cells immobilised on various porous cellulosic materials and their alginate/poly-lactic acid composites

Porous delignified cellulose (or tubular cellulose, abbr. TC) from Indian Mango (Mangifera indica) and Sal (Shorea robusta) wood and Rice husk, and TC/Ca-alginate/polylactic acid composites, were used as Lactobacillus bulgaricus immobilisation carriers leading to improvements in lactic acid fermentation of cheese whey and synthetic lactose media, compared to free cells. Specifically, shorter fermentation rates, higher lactic acid yields (g/g sugar utilised) and productivities (g/Ld), and higher amounts of volatile by-products were achieved, while no significant differences were observed on the performance of the different immobilised biocatalysts. The proposed biocatalysts are of food grade purity, cheap and easy to prepare, and they are attractive for bioprocess development based on immobilised cells. Such composite biocatalysts may be used for the co-immobilisation of different microorganisms or enzymes (in separate layers of the biocatalyst), to efficiently conduct different types of fermentations in the same bioreactor, avoiding inhibition problems of chemical or biological (competition) nature.

Mixed culture of Kluyveromyces marxianus and Candida krusei for single-cell protein production and organic load removal from whey

The study was conducted to evaluate the potential of mixed culture of Kluyveromyces marxianus and Candida krusei to enhance COD removal efficiency, minimize contamination at extreme conditions (high temperature 40°C and low pH 3.5) during batch and continuous aerobic fermentation and to obtain improved quality single-cell protein (SCP) using whey as substrate. The batch fermentation of mono-culture and mixed culture result showed that the mixed culture resulted in 8.8% higher COD removal efficacy with 19% higher biomass yield and 33% increased productivity. The maximum COD removal 80.2% (including residual protein) was obtained at 24h HRT with biomass productivity of 0.17 g/L/h; however, maximum biomass productivity of 0.38 g/L/h and 34% COD removal were obtained at 6h HRT. The results showed that the mixed culture of acid resistance and thermo-tolerant yeasts was a potential way to produce SCP (animal feed) and simultaneous COD removal under extreme operating conditions.

Solid state fermentation of food waste mixtures for single cell protein, aroma volatiles and fat production

Growth of selected microorganisms of industrial interest (Saccharomyces cerevisiae, Kluyveromyces marxianus and kefir) by solid state fermentation (SSF) of various food industry waste mixtures was studied. The fermented products were analysed for protein, and nutrient minerals content, as well as for aroma volatile compounds by GC/MS. The substrate fermented by K. marxianus contained the highest sum of fat and protein concentration (59.2% w/w dm) and therefore it could be considered for utilisation of its fat content and for livestock feed enrichment. Regarding volatiles, the formation of high amounts of ε-pinene was observed only in the SSF product of kefir at a yield estimated to be 4 kg/tn of SSF product. A preliminary design of a biorefinery-type process flow sheet and its economic analysis, indicated potential production of products (enriched livestock feed, fat and ε-pinene) of significant added value.

Maximizing hydrogen production and substrate consumption by Escherichia coli WDHL in cheese whey fermentation

Fermentative hydrogen production is strongly affected by pH. In order to maximize hydrogen production and substrate consumption in Escherichia coli ΔhycA, ΔlacI (WDHL) cheese whey fermentation, the influence of pH control at values of 5.5, 6, and 6.5 was studied in batch stirred-tank bioreactors. From the conditions evaluated, pH 6.5 was the best condition, at which the highest cumulative hydrogen production and yield (1.78 mol H2/mol lactose) were obtained. Moreover, at this pH, all carbohydrates from the cheese whey were consumed, and a mix of ethanol and organic acids, mainly lactate, were produced from glucose, whereas galactose yielded acetate, ethanol, and succinate. Operating the reactor at pH 5.5 resulted in the highest maximum specific production rate, but smaller hydrogen yield because only glucose was metabolized and galactose was accumulated. At pH 6, not all cheese whey carbohydrates were consumed, and it was not favorable for hydrogen production. Lactose consumption and growth kinetics were not affected by the pH. The results show the importance of controlling pH to maximize hydrogen production and substrate consumption using cheese whey as substrate.

Discarded oranges and brewer's spent grains as promoting ingredients for microbial growth by submerged and solid state fermentation of agro-industrial waste mixtures

The exploitation of various agro-industrial wastes for microbial cell mass production of Kluyveromyces marxianus, kefir, and Saccharomyces cerevisiae is reported in the present investigation. Specifically, the promotional effect of whole orange pulp on cell growth in mixtures consisting of cheese whey, molasses, and potato pulp in submerged fermentation processes was examined. A 2- to 3-fold increase of cell mass was observed in the presence of orange pulp. Likewise, the promotional effect of brewer's spent grains on cell growth in solid state fermentation of mixtures of whey, molasses, potato pulp, malt spent rootlets, and orange pulp was examined. The cell mass was increased by 3-fold for K. marxianus and 2-fold for S. cerevisiae in the presence of these substrates, proving their suitability for single-cell protein production without the need for extra nutrients. Cell growth kinetics were also studied by measurements of cell counts at various time intervals at different concentrations of added orange pulp. The protein content of the fermented substrates was increased substantially, indicating potential use of mixed agro-industrial wastes of negligible cost, as protein-enriched livestock feed, achieving at the same time creation of added value and waste minimization.

Kefir immobilized on corn grains as biocatalyst for lactic acid fermentation and sourdough bread making

The natural mixed culture kefir was immobilized on boiled corn grains to produce an efficient biocatalyst for lactic acid fermentation with direct applications in food production, such as sourdough bread making. The immobilized biocatalyst was initially evaluated for its efficiency for lactic acid production by fermentation of cheese whey at various temperatures. The immobilized cells increased the fermentation rate and enhanced lactic acid production compared to free kefir cells. Maximum lactic acid yield (68.8 g/100 g) and lactic acid productivity (12.6 g/L per day) were obtained during fermentation by immobilized cells at 37 °C. The immobilized biocatalyst was then assessed as culture for sourdough bread making. The produced sourdough breads had satisfactory specific loaf volumes and good sensory characteristics. Specifically, bread made by addition of 60% w/w sourdough containing kefir immobilized on corn was more resistant regarding mould spoilage (appearance during the 11(th) day), probably due to higher lactic acid produced (2.86 g/Kg of bread) compared to the control samples. The sourdough breads made with the immobilized biocatalyst had aroma profiles similar to that of the control samples as shown by headspace SPME GC-MS analysis.

Xanthan production by Xanthomonas campestris using whey permeate medium

Xanthan gum is a polysaccharide that is widely used as stabilizer and thickener with many industrial applications in food industry. Our aim was to estimate the ability of Xanthomonas campestris ATCC 13951 for the production of xanthan gum by using whey as a growth medium, a by-product of dairy industry. X. campestris ATCC 13951 has been studied in batch cultures using a complex medium for the determination of the optimal concentration of glucose, galactose and lactose. In addition, whey was used under various treatment procedures (de-proteinated, partially hydrolyzed by β-lactamase and partially hydrolyzed and de-proteinated) as culture medium, to study the production of xanthan in a 2 l bioreactor with constant stirring and aeration. A production of 28 g/l was obtained when partially hydrolysed β-lactamase was used, which proved to be one of the highest xanthan gum production reported so far. At the same time, an effort has been made for the control and selection of the most appropriate procedure for the preservation of the strain and its use as inoculant in batch cultures, without loss of its viability and its capability of xanthan gum production. The pre-treatment of whey (whey permeate medium hydrolyzed, WPH) was very important for the production of xanthan by the strain X. campestris ATCC 13951 during batch culture conditions in a 2 l bioreactor. Preservation methods such as lyophilization, cryopreservation at various glycerol solution and temperatures have been examined. The results indicated that the best preservation method for the producing strain X. campestris ATCC 13951 was the lyophilization. Taking into account that whey permeate is a low cost by-product of the dairy industry, the production of xanthan achieved under the studied conditions was considered very promising for industrial application.

Kefir grains as a starter for whey fermentation at different temperatures: chemical and microbiological characterisation

We report here a comparative analysis of the growth, acidification capacity, and chemical and microbiologic composition between kefir grains after 20 subcultures in whey at 20, 30, and 37°C and the original kefir grains coming from milk along with a determination of the microbiological composition of the fermented whey as compared with that of traditional fermented milk.

When fermentation was carried out repeatedly at 30 or 37°C, kefir grains changed their kefir-like appearance, exhibited reduced growth rates, had a lower diversity of yeasts and water content, and a higher protein-to-polysaccharide ratio compared with the original kefir grains. In contrast, at 20°C kefir grains could remain in whey for prolonged periods without altering their acidification capacity, growth rate, macroscopic appearance or chemical and microbiologic composition—with the only difference being a reduction in certain yeast populations after 20 subcultures in whey. At this incubation temperature, the presence ofLactobacillus kefiranofaciens, Lb. kefir, Lb. parakefir, Lactococcus lactis, Kluyveromyces marxianus, Saccharomyces unisporus, andSac. cerevisiaewas detected in kefir grains and in fermented whey by denaturing-gradient-gel electrophoresis (DGGE). In whey fermented at 20°C the number of lactic-acid bacteria (LAB) was significantly lower (P<0·05) and the number of yeast significantly higher (P<0·05) than in fermented milk. Since the DGGE profiles were similar for both products, at this temperature the microbiologic composition of fermented whey is similar to that of fermented milk. We therefore suggest a temperature of 20°C to preserve kefir grains as whey-fermentation starters.