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Large-Scale Production and Application of Immobilized Lactase
Large-Scale Production and Application of Immobilized Lactase
Large-Scale Production and Application of Immobilized Lactase
[38] L a r g e - S c a l e P r o d u c t i o n a n d A p p l i c a t i o n o f
Immobilized Lactase
By J. L. BARET
TABLE I
MAIN CHARACTERISTICS OF LACTASES AND IMMOBILIZED LACTASES
pH pH Temperature pH
Source Status a optimum stability optimum optimum Activity b
Engineering Considerations
The development of immobilized lactase processes is basically depen-
dent on several parameters: the operational characteristics of the immobi-
lized lactase composite, the nature of the substrate feedstocks, the design
of the reactor system, and the operating strategy. The overall perfor-
mance of the system is the result of the interaction between these differ-
ent parameters and determines the economy of the process. The key
objective is to maximize the amount of hydrolyzed lactose which is pro-
cessed per unit weight of catalyst. A long operational life is necessary to
reach this objective. The deactivation of the immobilized lactase is mainly
influenced by the operating temperature and pH, the nature of the feed,
and the development of microbial contaminations.
In industrial practice, several processes based on immobilized enzyme
reactors are currently being used. The reactors have two points in com-
mon. First, a substrate feedstock of controlled purity is processed, and
second, the development of microbial contaminations can be controlled
because the substrate media are deficient and/or a selective environment
can be used (temperature, pH, substrate concentration, microbial inhibi-
tots). The situation using wheys and permeates is very different. These
media are nutritionally rich and thus are excellent growth media for mi-
croorganisms. The possibility of controlling the development of microbial
contaminations at low pH (below pH 3.5) and at temperatures above 35 °6
5 H. H. Weetall, N. B. Havewala, W. H. Pitcher, C. C. Detar, W. P. Vann, and S. Yaver-
baum, Biotechnol. Biogen. 16, 295 (1974).
[38] PRODUCTION--APPLICATION OF IMMOBILIZED LACTASE 415
Feed Substrate
Different lactose-containing feedstocks have been evaluated. The
main characteristics of these feeds are reported in Table II. The complex-
ity of the feed increases as a function of the presence and concentrations
of salts (defined as ashes), nitrogenous matter (total nitrogen x 6.38), true
proteins (proteinaceous nitrogen × 6.38), and suspended solids.
The highly demineralized permeates are for practical purpose very
close to a pure lactose solution. However, their use may be limited be-
cause they are costly to produce by current ion-exchange techniques. In
order to widen the applications of the technology it was important to
develop processes that were adapted to the other different substrate
feeds. Processing of permeates and electrodialyzed permeates showed
that the presence of salts and different concentrations of cations and
anions normally found in these feeds had no adverse effect on the perfor-
mance and stability of the enzyme. The need for demineralization is there-
fore related to the application of the end product.
The level of suspended solids in wheys and the presence of the col-
loids in sweet whey were found to be of particular importance during
operations in a fixed bed reactor. Microbial contaminations in the feed
also has a critical impact as the main source of contamination.
Reactor Design
Reactors were designed in order to test the long-term stability perfor-
mance of the immobilized lactase and the economics of the processes
under industrial conditions. The design of the reactor aimed at maximiz-
ing the performances of the immobilized lactase reactor while minimizing
or controlling at the same time operational problems such as microbial
contaminations, pressure drops, and plugging. Three main types of reac-
tors were considered: fixed bed, fluidized bed, and stirred tank reactors
(Table III).
A perfect fixed bed reactor behaves ideally as a plug flow reactor. An
ideal continuous stirred tank reactor would behave as a perfect backmix
reactor. Some backmixing is observed in fluidized bed reactors and the
extent of bed expansion affects the performance. From a kinetic stand-
z
z O
b,
Z
0
O
,.= k~
o~
m
H
e~
o~
.r.,
©
[38] PRODUCTION-APPLICATION OF IMMOBILIZED LACTASE 417
TABLE III
COMPARATIVE PERFORMANCES OF CONTINUOUS STIRRED TANK AND
PLUG FLOW REACTORSa
Normalized residence
timeb (units/ml-hr)
Degree of Relative amount:
conversion Continuous continuous stirred
(%) stirred tank Plugf l o w tank/plug flow reactor
50 14 6.4 2.2
60 24.2 9.8 2.5
70 42.6 14.8 2.9
80 81.6 22.6 3.6
90 202.8 37.6 5.4
(E/F)pF = ~ I_ Ki SoX + \ Ki +
point a plug flow reactor appears to be the most efficient at minimizing the
immobilized lactase requirement and the volume of the reactor. H o w e v e r ,
fixed bed reactors are k n o w n to be sensitive to the presence of suspended
solids which m a y be present in feeds. This aspect was found to be of
i m p o r t a n c e with w h e y feeds, so p r e t r e a t m e n t of w h e y feeds b e c a m e nec-
essary to run satisfactory operations in a fixed bed mode.
Microbial Contaminations
Sources of Contamination
T h e r e are three main sources of microbial contamination that m a y
affect the operations at industrial scale: microorganisms normally present
in the feed substrate, microorganisms present in the reactor or adsorbed
on the carrier, and accidental contamination occurring during the han-
dling of the lactase c o m p o s i t e or other operations.
418 ENZYME ENGINEERING(ENZYME TECHNOLOGY) [38]
Operating Strategy
T A B L E IV
HYDROLYSIS OF RAW WHEY AT p H 3.5 AND 50 °
TABLE V
APPARENT DEACTIVATION DURING HYDROLYSIS OF CLARIFIED AND
DEMINERALIZED WHEY WITH IMMOBILIZED LACTASEa
s L. A. Dohan, J. L. Baret, S. Pain, and P. Delalande, Int. Enzyme Eng. Conf. 5th (1979).
9 j. L. Baret and L. A. Dohan, Brevet Franfais 2,483,748.
[38] PRODUCTION-APPLICATION OF IMMOBILIZED LACTASE 421
Temperature Program
The knowledge of both the activation energy and the thermal deactiva-
tion energy allows an estimation of the theoretical life of the enzyme as a
TABLE VI
ACTIVITY AND STABILITY OF THE IMMOBILIZED LACTASE DURING
HYDROLYSIS OF WHEY IN RELATION TO DIFFERENT CLEANING AND/OR
DISINFECTING PROCEDURES
Column 1:
protease and Column 2: Column 3:
Day Tego-Diocto BS acetic acid Tego-Diocto BS
Activity (units/g)
1 235 258 174
5 296 202 143
10 233 163 125
15 220 117 122
17 223 36 (stop) 107
20 213 104
26 203 98
Half-life(days) 55 9 35
Stability (%)0 96 60 90
function of the initial operating temperature. The theoretical life will in-
crease when the initial operating temperature decreases, so initial low
temperature operation is necessary to maximize the productivity. How-
ever, in practice, a pure thermal deactivation of the enzyme may not be
the only controlling phenomenon at low temperature. The initial produc-
tivities of the reactors were maintained constant at specified values by
raising the temperature when it was necessary. Actual gains in activities
were about 5-10% per degree centigrade in the range of operating tem-
peratures which were considered (20-45 °) with various feeds.
This operating temperature approach in conjunction with an adequate
cleaning-sanitation process made it possible to keep the performances of
the reactors constant over periods of time sufficient to demonstrate the
economic feasibility of the process.
Industrial Developments
These semiindustrial operations increased our confidence in the tech-
nology for hydrolyzing wheys and permeates. The technology was trans-
ferred to full-scale operations. Corning established joint ventures with
major partners in the food industry: the Specialist Dairy Ingredient com-
pany (SDI) with the Milk Marketing Board in England, the Nutrisearch
Company with the Kroger Company in the United States, and Corvire
with Union Laiti~re Normande (ULN) in France.
A plant processing 20,000 liters/day of sweet whey is operated by SDI
at Aston (Cheshire). The hydrolysis reactor can process 1000 liters/hr of
nondemineralized acidified sweet whey with a load of about 40 kg of
lactase composite. Lactolyzed whey products are obtained, and are for-
mulated as "sweet-protein" syrups which can be used as ingredients in
different sectors of the food industries. The SDI production was used to
develop the market for this new product in confectionary, ice cream, and
baked products. Capacity expansion is under way.
The most advanced operation is the Nutrisearch plant in Winchester,
Kentucky, which combines the immobilized lactase technology of Corn-
ing and continuous fermentation technology of Kroger Co. Investments
for that plant were 15 million dollars for a nominal capacity of 100,000
gallons of raw cottage cheese whey per day. Whey is processed by ultra-
filtration to obtain a protein-rich retentate. This stream is then formulated
as a dried whey protein concentrate. The permeate stream is pumped into
two hydrolysis columns. These columns are 3-ft-diameter and 15-ft-high
vessels filled with about 1500 kg of lactase composite. The lactolyzed
permeate stream can then be fermented by a selected Saccharomyces
cerevisae strain in a continuous fermenter to produce baker's yeast.
[39] UHT STERILIZED MILK TREATMENT USING SOX 423