Filtration Improvement in theFermentation Process

With Enzyme manufacturing the fermentation process is a critical component to delivering a desired product that meets specification. However fermentation operations are continously being challenged with meeting precise process conditions, demands of higher volumes and decreasing costs while maintaining the integral products being produced. Contamination from competing microbes put process yields at-risk and as a result profits can quickly diminish. The purity of both process liquids and air is critical to the success of the company.

PROCESS CHALLENGES Enzyme manufacturing is a highly technical, complex and costly operation requiring attention to detail to ensure pure and quality products. With industrial grade enzyme manufacturing, the fermentation-based process requires a small volume of inoculum (bacteria) immersed in a controlled medium that supports abundant enzyme growth. Bacterium, like Aspergillus niger, are subjected to a carbohydrate based medium in specific and controlled conditions (i.e. pH, temperature, oxygen content and nutritional ingredients) that multiply enzyme production. Once populated, the enzyme is separated from the ‘dead cells’ and further purified through separation by both centrifugation and continuous filtration techniques. The operation is costly with high margins, leaving minimal room for process interruptions. Achieving a smooth process requires a sound maintenance budget and schedule.

Routine maintenance reduces process interruption and it is imperative the enzyme manufacturer’s equipment operates smoothly to protect product quality. Per regular maintenance schedules, filter housings are inspected for increased differential pressure caused by accumulated particulate retention. Filter housings and filters are also steam sterilized after each batch process to reduce contamination. Production batches can be valued at several hundred thousand dollars and the slightest negative alteration in process conditions, such as being subjected to microbial and/or foreign particulate can contaminate and compromise product quality potentially leading to a complete loss of product.

BENEFITS OF AN OPTIMUM FILTRATION/SEPARATION SYSTEM:

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Protect Process Equipment

Minimize System Downtime

Lower Operating and Maintenance Costs

Improve Product Quality and Consistency

THE SOLUTIONFor over 10 years, Global Filter has proven our committment to supplying high quality filtration products for enzyme manufacturers. Having a well established customer relationships with key enzyme manufacturers and they know they can count on Global Filter to deliver exemplary product with knowledgeable technical aptitude to help solve filration related process issues. Global Filter has also built these trusted relationships by providing minimal lead times and competitive price structure. With these high volume operations requiring both liquid and air filtration, Global Filter is able to supply more economical prefiltration solutions such as meltblown and pleated polypropylene depth media filters to remove larger particulate. In addition, for compressed air and tank venting filtration, Global Filter can use is portfolio of soltuions to provide high purity hydrophobic membrane elements in either polysulfone or PTFE.

Global Filter’s PTFE membranes are integrity tested and have been validated for both bacterial reduction above a log reduction value (LRV) of 7 and even more rigorous testing to achieve a completely validated filter cartridge that meets sterilization requirements. Sterilizing grade filters are proven to remove equal to or above an LRV of 7 and have been validated in accordance with HIMA and ASTM F838-05 guidelines. Global’s sterilizing grade filter was also aerosol challenged with a MS2 bacteriophage. Polyethersulfone membrane filters also used for final liquid filtration before enzymes are further purified downstream via ultra- and nanofiltration. Global Filter’s products are known for handling higher flow rates while maintaining low pressure drops. These characteristics helps reduce the enzyme manufacturer’s maintenance down times and operation costs due to less energy consumption. It is due to this rigorous testing, high quality construction and responsiveness that enzyme suppliers trusts Global Filter with their filtration needs, protecting their most valued process entity. Global Filter’s products meet these demands and other aggressive industrial environments where robust construction yet attention to fine detail matter.

The purity of both process liquids and air is critical to the overall success of the company.

Enzyme Manufacturing 04/18

With high volume operations requiring both liquid and air filtration Global Filter is able to supply more economical prefiltration solutions

Enzyme Manufacturing 04/18

4

FILTER

NutrientTank

Fermentation Tank

DE TrapFilter

H2O

3

FILTER

2

FILTER

DE Filter

11

FILTER

Global PP or MBElements

Global PTFE or PSH Elements

Global PTFEor PSH Elements

GlobalPES

Elements

GlobalPP or FGElements

GlobalPP or FGElements

10

FILTER

5

FILTER

StorageTank

Prefilters

7

FILTER

GlobalPES

Elements

GlobalPP or FGElements

6

FILTER

Gas Duct

Air 1FILTER

Global PTFE or PSH Elements

9

FILTER

GlobalPES

Elements

GlobalPP or FGElements

8

FILTER

PrefiltersPrefilters

Drums for final product

MicrofiltrationUltrafiltration

GLOBAL FILTER SOLUTIONS FOR THE FERMENTATION PROCESS

This schematic should be viewed as a general example of where filtration systems could be located within a fermentation process. These processes will vary between companies and facilities. As such, each appli-cation should be reviewed and considered individually in order to choose the correct system technology.

Filter Solutions for Stages of the Fermentation Process

Location Global Filter Solutions Filter Purpose Filter Benefit

1. Inlet Air

PTFE Hydrophobic Membrane General Grade • GGPTFE, BRPTFE, PPTFE Series

PS Hydrophobic Membrane • Polysulfone - PSH Series

Removal of particulated such as sediment, suspended solids, pipe scale, etc. from process water

Maintains aeration efficiency for bacterial growth and production

2. Inlet H20

Polypropylene Meltblown • GWTB, GCTB, GATB Series

Pleated Polypropylene • PP, PPE Series

Removal of particulate and bateria from process air

Maintains water quality as an ingredient

3. - 4. Fermentation

Tank

PTFE Hydrophobic Membrane General Grade • GGPTFE, BRPTFE, PPTFE Series

PS Hydrophobic Membrane • Polysulfone - PSH Series

Fermentation tank vent filtration

Allows for bacteria free air passage during filling and evacutaiton, protecting the fermentation tank and its contents from contamination

5. DE Trap Filter

Pleated Microglass • FG, FGE Series

Pleated Polypropylene • PP, PPE Series

Installed downstream of the Diatomaceous Earth (DE) filter to prevent DE bleed-through fines from entering product

Maintains high quality of the process and minimized sediment and poor quality perception of the final product

6. - 11. Pre and Post

Filtration to Micro and Ultrafiltration

Pleated Microglass • FG, FGE Series

Pleated Polypropylene • PP, PPE Series

Pleated Polyethersulfone • GWPES, WCPES, GGPES, GFPES, GBPES, BRPES, PPES Series

Removal of coarse and fine particulate

Pre-filtration of finished product before micro and ultrafiltration