Dr.

Reda Mahgoub Mohamed

Production of baker’s yeast by fermentation
 Yeast is a key ingredient for the production of bakery products and plays an important
role in CO2 production, dough maturation, and fermentation flavor. CO2 is generated by
yeast as a result of the breakdown of fermentable sugars in the dough. The evolution of CO2
causes an expansion of the dough trapped within the protein matrix. Dough maturation is
accomplished by the chemical reactions of yeast producing alcohols and acids from the
proteins of flour, and by the physical stretching of protein and CO2, which results in the light
and airy physical structure associated with yeast-leavened products. Yeast also gives bread its
characteristic flavor. During dough fermentation, yeast produces many secondary metabolites
such as ketones, higher alcohols, organic acids, aldehydes, and esters.
Some of them escape during baking. Others react with each other and with other compounds
to form new and complex flavor compounds. These reactions occur primarily in the crust
and crumb of baked breads.
Baker’s Yeast is a commercial preparation consisting of dried cells of one or
more strains of Saccharomyces cerevisiae. Bakers use yeast as a leavening agent
in the rising of dough for baking. A secondary contribution of yeast to bread is
flavoring and aroma.
 Requirements for bakery yeast production
1. Yeast type, Saccharomyces cerevisiae
2. Nutrients and substrate
3. Sugar concentration 0.5 to 1.5%
4. Aeration
5. pH 3.5 to 4.5
6. Temp. 25 – 30°C.
7. Lactic acid bacteria
 Baker’s yeast production using molasses
Cane or beet molasses is the primary raw material and S. cerevisiae is the
main yeast strain for baker’s yeast production. Molasses contains 45 to55
weight percent fermentable sugars, in the forms of sucrose, glucose, and
fructose and it supplies all the sugar that yeast needs for growth and
energy along with part of the needed nitrogen. The amount and type of
cane and beet molasses used depend on the availability of the molasses
types, costs, and the presence of inhibitors and toxins.
Usually, a blend consisting of both cane and beet molasses is used in the fermentations.
Before it is fed to the yeast, concentrated molasses is diluted with water, heat treatment,
clarified, filtration and heat sterilized.

A variety of essential nutrients and vitamins is also required in yeast production.

The nutrient and mineral requirements include nitrogen, potassium, phosphate,

magnesium, and calcium, with traces of iron, zinc, copper, manganese, and
molybdenum.
 Ammonia and molasses method

Normally, nitrogen is supplied by adding ammonium salts, aqueous

ammonia, or anhydrous ammonia to the feedstock.
After fermentation, the yeast is fully-grown and the suspension is subsequently
centrifuged in order to separate the yeast from the remainders of molasses.
The yeast cream is quickly cooled down to 4°C and stored in refrigerated tanks.
The yeast cream in those refrigerated tanks is then processed into 3 kinds of yeast
products.
Part of the yeast cream is sold as liquid yeast. The remaining yeast cream is further
processed into fresh or dry yeast.
 Cream yeast is not typically called a ‘baker’s yeast product’
but is relevant as it represents a major step in the process
and is a marketable product itself.

At the end of the fermentation, the yeast broth is

concentrated using a series of combined centrifugation and
washing steps, into a yeast cream with a solids
concentration of approximately 22%.
The yeast is then cooled to 4°C, in order to restrict the
Cream Yeast
growth of any contaminating microorganisms.
 The cooled yeast cream is stored in a hygienic storage tank, which is
insulated and equipped with agitators and cooling pipes, effectively
preventing heat exchange with the surrounding atmosphere, keeping the
cream at 4°C.
Cream Yeast is basically the liquid product and can therefore be transferred
into containers and distributed to bakeries, where it is used to produce yeast
based products.
The advantage of this is that it excludes any human handling and therefore
reduces the risk of contamination by handling, however due to its high
volume, transport costs can be expensive.
Once an optimum quantity of yeast has been grown, the yeast cells are recovered from
the final fermenter. The centrifuged yeast solids should be concentrated by filter press
or rotary vacuum filter. A filter press forms a filter cake containing 27% to 32% solids,
whereas a rotary vacuum filter cake contains approximately 33% solids. The filter cake
should be blended in mixers with small amounts of water, emulsifiers, and cutting oils to
form the end product. In compressed yeast production, emulsifiers are added to give the
yeast a white and creamy appearance. A small amount of oil is added to help extrude the
yeast to form continuous ribbons. The ribbons are cut into pieces, wrapped, and cooled
to less than 8°C. The yeast is extruded in thin ribbons and dried in a batch or continuous
drying system. The yeast should be packed under vacuum or nitrogen gas before heat
sealing. The shelf life at ambient temperature is 1 to 2 years.

Volatile organic compound emissions, that is, ethanol and acetaldehyde are generated
as by-products of the fermentation process. Other by-products such as butanol,
isopropyl alcohol, 2,3-butanediol, organic acids, and acetates are also generated
during the fermentation process. Volatile by-products form as a result of either excess
sugar (molasses) present in the fermenter or because of an insufficient oxygen supply.
Instant dry yeast Liquid yeast

Compressed yeast Crumbled yeast

Production of carbon dioxide
Carbon dioxide is generated by the yeast as a result of the breakdown of
fermentable sugars in the dough. The evolution of carbon dioxide causes
expansion of the dough as it is trapped within the protein matrix of the
dough.
     
 Causes dough maturation
This is accomplished by the chemical reaction of yeast produced alcohols
and acids on protein of the flour and by the physical stretching of the
protein by carbon dioxide gas.
This results in the light, airy physical structure associated with yeast
leavened products.
 Development of fermentation flavor
  

Yeast imparts the characteristic flavor of bread and other yeast leavened products.
During dough fermentation, yeast produce many secondary metabolites such as
ketones, higher alcohols, organic acids, aldehydes and esters. Some of these,
escape during baking.
Others react with each other and with other compounds found in the dough to form
new and more complex flavor compounds. These reactions occur primarily in the
crust and the resultant flavor diffuses into the crumb of the baked bread.