Fermentation
Discover effective applications in fermentation production.
Fermentation transforms simple ingredients into delicious products including cheese, salami, kombucha, tempeh, sourdough bread, yogurt, kimchi, wine, and beer. Recently, fermentation has emerged as a method for generating new protein sources using microorganisms. What makes fermentation remarkable is its sustainability. This age-old method can produce proteins in a matter of hours, far quicker than traditional protein production techniques. This efficiency leads to a low carbon footprint, minimal land usage, and reduced greenhouse gas emissions. Plus, it doesn't demand expanding arable land, making it an incredibly resource-efficient choice.
Fermentation-derived alternative protein products are reliable, weather-independent, and can be produced year-round. They are already used globally and support a circular economy by utilizing low-cost industrial or agricultural byproducts, reducing production costs and carbon footprints. The global market for these products is anticipated to reach around 120.8 billion USD by 2033, growing at a CAGR of 43.50% from 2024 to 2033.
The fermentation process for producing alternative proteins can be broadly classified as:
Biomass fermentation: Proteins contain the whole cell (bacteria, yeast, fungi/ mycelium) as the final product after removing the impurities. They are sometimes referred to as single-cell proteins, as the entire cell comprises a variety of proteins and peptides.
Precision Fermentation: Proteins are produced by inserting specific genes into microorganisms to create analogs like enzymes, whey, casein, lactoferrin, egg albumin, and growth factors for the cultivated meat industry. A notable example is the enzyme ‘rennet,’ used in cheese production since the 1980s, which reduced reliance on cows and established a cruelty-free, stable supply chain.
The key factors in fermentation-derived protein production are the feedstock and source optimization, microbial strain and its growth characteristics, bioreactor and process design, protein extraction and product formulation. Membranes are essential for the selective separation and purification of proteins from impurities. Pall's Membralox® ceramic membranes are widely used in the fermentation industry due to their cost-effectiveness, sustainability, and energy efficiency, which enhance yield and product quality. Microfiltration and ultrafiltration aid in clarifying and concentrating proteins while removing contaminants. In precision fermentation, microfiltration is crucial for eliminating GMO components from the final product, particularly in regions like the EU, where GMOs are prohibited.
Pall’s Membralox® crossflow filtration systems for highest protein transmission are fully enclosed and automatized. The membranes are, regularly cleaned and sanitized in place with lower labor requirements. Additionally, the process is operated at suitable temperatures to prevent any thermal denaturation of the product while maximizing separation performances. Their modular design enables a wide range of flow rates generally at constant throughput, possibly in full continuous mode (24/7). Membranes’ lifetime extends over years of continuous operation with consistent separation performances and capacity.
In summary, Pall’s Membralox® ceramic membranes advantages in the production of alternative proteins include the following:
- Highly selective and scalable solutions with handling capacities up to several thousands to millions per unit per day
- Highest protein transmission in combination with a significant retention of microbiological burden
- Clean-In-Place (CIP) that can handle extreme pH, chemicals and temperatures, ensuring a clean transition between the runs
- Better long-term ROI
- Environmentally sustainable
- Recovery/extraction and separation of the different types of proteins (albumins Vs. globulins)
- High protein purity and functionality with minimal to no protein denaturation
- Lower OPEX due to lower usage of energy, water and carbon footprint. Membrane separation optimizes drying, reducing water and energy with shorter processing times.
Contact our filtration experts to discuss the fermentation filtration options suitable for your production needs.