REHABILITATION (AGAIN) OF TAMAN JAYA LAKES

REHABILITATION (AGAIN) OF TAMAN JAYA LAKES I am not at all impressed by the continuous futile efforts in trying to rehabilitate the Taman Jaya Lakes. I see the problem could be solved only by thorough understanding of science and engineering processes involved. This means thorough scientific studies and experimental studies in the laboratories as well as in the field before proper permanent action and solution can be carried out. The absence of quantitative data or statistics is a serious error. In the world of business and sales talks the ‘promises’ should not be accepted wholesale. Once the business deal is signed that will be probably the last you will ever see the salesmen or their knockings on the door The gimmick of the boat tide involving important officers high above is just a waste of time and a cheap publicity stunt. The lake is not even that big……. Remember! Cleaning the Taman Jaya lake is not as simple as a ‘Micky Mouse Project’ Type rest of the post here. Read more!

VISCOSITY OF FERMENTATION BROTH AND THE CHOICE OF THE RIGHT IMPELLER

It is sad to observe that most students or even researchers in fermentation technology, downplay the importance of viscosity of the fermentation broth and the choice of the right impeller. They seem to have the opinion that viscosity characterization and impeller design and configuration is not crucial to the optimization of the fermentation process. They are led in the blind belief that that the Rushton impeller is the best for all situations. Perhaps they are not aware there are many critical designs of impellers which is not only making mixing efficient but even optimizing in terms of energy saving and costs. This is especially crucial now where the cost of energy in increasing all the time which could make or break the economics of the fermentation industries
Every impeller has its own unique characteristics in terms of its mixing, flow. One impeller does not suit all! We have to determine the choice of proper impeller by carrying laboratory experimental studies.

There is usually a change in impeller design as the viscosity increases. Usually under low viscosity fermentation broth the common choice of impellers are propellers and flat blade impellers. But as the viscosity increases the choice of impellers are more towards gte anchors and helical screws or ribbons

The analyses of the viscosity of the fermentation broth are crucial at this stage of determination. We have to determine its rheological pattern and the changes of viscosity with time in coming with the right impeller. But most often this is not done…. It is a known fact viscosity changes with time in any fermentation process. A good fermenter which is energy efficint should hav a stirrer which is adaptable to changes in viscosity

The obsession is more on scaling up studies without fully understanding the scaling up process, and to rely on rules of the thumb.


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BIOFUEL FROM ALGAE- MORE LIMITATIONS THAN POSSIBILITIES

If I am not mistaken, this is the second time when the possibility of using algae in biotechnology exploitation is receiving massive publicity. In the early seventies the focus is more in the production of SCP or single cell protein for animal feed. Nowadays, there is more talk about getting biofuel from the algal cells.
In theory this is a good idea as algal cells in the presence of light used photosynthesis to use carbon dioxide and release oxygen. In return not only you get the spin off benefits which are not only environmental friendly but even produce products as the substrate for fermentation to generate energy. It is simply a great ‘win- win’ situation for all.
However, in reality things are simply not as easy as it looks. From the point of mass culturing of the algal cells we have to depend on special bioreactors or fomenters called photo bioreactors. It is the kind of bioreactor where the algal culture are grown and mixed or circulated under conditions of light source to illuminate the algal culture for its source of energy.
The problems of bioreactors are clearly more seen at the level of scale up or using industrial size photobioreactors
At a large scale there are going to be problems faced in photo bioreactors. As we know the ideal photobioreactor is to get well mixed condition that encourage mass transfers. It is clear that there will be problems faced due to the lack of mechanical stirrers to carry out this job.
Using mechanical stirrers might create problems of shear forces which can break up the algal cells.
There is also the problem of supplying carbon dioxide mass transfers to supply to the algal cells at the scale of large photobioreactors
Light penetration into the medium is a real engineering biochallenge. Algal cell as suspended solids tend to block the penetration of light to all the algal cells.
The medium used for the algal cultivation must also clear enough to allow light penetration while at the same time provide nutrients to the algal cells
Sad to say, despite the potential or promises that algal cells can be used for biofuel it is still basically studies carried on laboratory scale and require a lot more research and heavy capital investments
Just because you are living in the sunny tropical country doesn’t always guarantee that the cultivation of algal cell by photo bioreactors is practical!!!



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FERMENTATION TECHNOLOGY COMES IN MANY GUISES

Due to the popularity of subjects like biotechnology, microbiology, bioprocess engineering, there are now many public and private universities offering such courses. Most of these courses or degrees have fermentation technology as a subject in their degree.
But if we bother to surf the websites for additional information and curricula on fermentation technology, we will find that despite the universality of the subject the syllabus varies and so are their fermentation technology facilities.
Some of the laboratories seemed so empty and lacking serious equipments!!!
Surprisingly in most of these universities they do not have sufficient or even fermenters. The practicals or subject of fermentation technology is more a food microbiology course with practicals involving alcoholic fermentation or tapai
What is even more disturbing is the basic subjects needed to do fermentation technology vary. Either the department has no idea what is the basic subject requirement for the fermentation technology course or that they just try to fit any existing subjects into the course. Whether these subjects are relevant is secondary
I often wonder how the division in the education ministry in charge of ensuring the quality of the degrees gives the approval for these courses.
The tragic thing is that most students will not be able to learn fully the subject and even if they worked in the industries they will be laughed at….by their sheer ignorance of the subject.
So don’t blame anyone if they become pseudo fermentation technologists as they are taught by pseudo lecturers and pseudo departments in fermentation technology



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“TERMINATING” THE FERMENTATION PROCESS

Many food fermentation industries are facing the problem of when is the right time to terminate a fermentation process and how to terminate the fermentation process?. A fermentation process will keep going on and on until the substrate runs out or there are changes which occur in the fermenting food product which will lead to the slowing down and even the cessation of the fermentation process.
In many food and beverage fermentation once the desired fermentation product is achieved in terms of its nutritional, organo leptic properties, the fermentation broth or the product need to undergo downstream activities such as bottling and repackaging the product.
If the fermentation product is liquid or contain water, there is possibility that even after repackaging or bottling the fermentation process in the bottle or package might still continue. In view of this the continuing fermentation process might still continue changing the biochemical characteristics of the products.
In situation like this how the fermented product is kept under low temperature is important. It is important that the expiry date is adhered to
Then why don’t we just terminate the fermentation process itself? This is easier said than done. The question is how do we terminate the fermentation process? Will the process affect the quality of the fermentation product itself?
Many of the industries producing the fermentation products keep the secret of their fermentation process. Its not so much of the microorganism but the strains it used. They are not keen in allowing their strains in the fermentation products be released to public for free by just buying a few cents of yogurt.
It is important in their case that the strains used will die or becomes non viable once the fermentation is completed. How they do this is their trade secret. However a good microbiologist will be able to reisolate the strain 
Most of the fermentation process is ‘terminated’ by a few available technology such as manipulating the temperature or even using chemicals to inhibit the fermenting microorganisms without affecting the fermentation products.


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IMPROVING THE EFFICIENCY AND UPGRADING OF THE SMALL COTTAGE FERMENTATION INDUSTRIES

The small cottage industries producing fermented foods are facing their greatest challenges today. Not only they have to face the shrinking market due to competition from bigger or medium size fermentation industries, but they are also facing the barriers and limitations enforced by health and GMP. They have no choice that in order to survive they have to expand their market and even going global
However, being in the traditional fermentation industries, small in size and output they lack the capital support and even the scientific technical expertise to ensure their survival. Traditional fermentation cottage industries too are recalcitrant to changes, still practicing the same method of production of their ancestors
They can survive as they are now but they will not be able to expand their market and will always retain their small niche in the market.
Only by increasing their size of production, improving their fermentation process technology can they hope to compete successfully
There are few possibilities they can do to survive:
1 Pooling together of resources by cooperatives to increase the volume of fermented food
2By forming a consortium they can afford to improve their fermentation facilities and employ food scientists to optimize their production
3 pooling together will allow them to invest in expensive scientific equipment and improve their technology of production
4 pooling together will eliminate competition among themselves and instead form a synergy to compete with bigger players
5 pooling together will allow them to acquire transportation to distribute wider their goods and increase the market
They should realize that the big industry players were once small cottage fermentation industries like them but they are willing to risk and take the step further



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EDUCATIONAL VISITS TO INDUSTRIAL FERMENTATION PLANTS

It is generally accepted that educational visits to fermentation factories formed part and parcel of the course in fermentation technology. The objectives of the visits are more towards appreciating and reinforcing the understanding of fermentation technology being applied from what is learned in the lecture halls and the laboratories to real life situations in the fermentation industries
On one hand the visits by colleges and universities are often welcomed by the factories as it forms part of the public relations image and good marketing strategy. It also help to contribute positively to the education of fermentation technology.
However on the other hand, such visits are often regarded as ‘irritation’ to the factory management as there may be ‘secrets’ to hide from the probing eyes and minds of the visitors. The fear of being discovered in coveringcertain aspects of the production process could be disastrous especially nowadays with the ease of information being disseminate through the internet
The fermentation are happier if the visits for the fermentation technology students are the usual ‘walk and pass through’ sessions with little or no probing into the intimate details of the fermentation process. It is not often in their best interests to ‘tell all’ the details of the fermentation process.
So often it is not surprising the information given to the fermentation technology students are the same given to the public, school students and even the kindergarten students!
All will be happy with the visit where they will be served refreshments and ‘goody’packages containing samples of the fermentation products
But sadly, this is not benefitting to the fermentation technology students. Thy came there to visit, to understand and to learn.
In situations like this the fermentation technology students visiting the factories must be prepared to ask important aspects of the fermentation technology that is applied into the industrial process.
It is ideal before the visits are carried out the lecturer in charge brief the students what to expect and the questions that they should be looking into. At the end of the day detailed reports should be submitted to be examined.
In such cases the class should be divided into sub groups to look into various aspects of the fermentation process and the results combined together


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FERMENTATION ONLY MAKES SENSE WHEN IT’S BROKENDOWN TO DOLLARS AND CENTS

In any fermentation industry, if you are going to carry out a fermentation project it will have to be profitable or at least showing the potential of profitability. Fermentation industries are not charitable organizations that can carry out fermentation research for the purpose of esoteric activity. Money simply does not grow on trees and they have to account for their success or failures to the share holders. Esoteric research can only be carried out in public funded research institutes and universities where financial auditing is not strict and almost unaccountable (at least in this country)
Two of the weakest links in fermentation research here is that:
1 The scientists are very quick to extrapolate the profitability based on incomplete small scale research. This is risky since no scale up studies are properly carried out to test the technical viability of the process
2 They failed to audit the fermentation viability in terms of cost inputs but rather talk about potential market price. This is really a recipe for disaster! A lot of fermentations could be economically non viable if proper financial auditing is carried out
Do not talk about counting the chickens before they are hatched…it is just as good as a pipe dream!
If proper studies are carried out on the costings you might even see the project failure while still on paper
One of the most critical factors influencing the cost of fermentation is cost of energy. In the fermentation industries energy in the form of electrical power are required in so many steps of the fermentation flow
You need energy for heating, cooling, sterilizing, pumping, aerating, stirring and many more. So this must be considered as energy is a limited commodity and will increase in cost in future. Have these factors been thoroughly considered and taken into account before declaring to the world we have the technology to convert biomass to wealth by fermentation?






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QUESTIONS ABOUT EQUSAINS AIRLIFT CULTURE

In the recent BioMalaysia 2011, much attention has been given to the pictures of Prime Minister of Malaysia listening to the briefing and observing one of the exhibits which is the equsains airlift culture. The culture vessel is the product of University Sains Malaysia.
My curiosity is aroused leading me to learn more from the Pecipta exhibition conducted among the universities in Malaysia
The following is the description of the vessel as extracted direcly from the Pecipta:
Top Airlift Plant Propogation Culture Vessel was designed to provide proper contact and sufficient aeration between the culture and the liquid medium, all in a vesselto enhance better growth in an aseptic condition.
The aeration is provided via a 0.2 urn membrane through a glass tube at the lid and the cultures will be well aerated by the formation of fine air bubbles at the end of 4 funnel-shaped filters that are placed near the base of the culture vessel.
The excess air will be removed via a glass vent attached to the lid.
It is a very versatile system and can be used for the propagation of any plant species as long as the proliferation culture medium for that particular plant species is established. This portable culture vessel could be easily used and placed anywhere as long as there is a light source.
On reading in detail of the invention I was overwhelmed by the positive attributes associated with the use of the culture vessel such as the higher yield of plantlets obtained within a shorter period compared to normal plant culture
There seems to be no flaws or no reports with the problems and limitations of using the equisains culture vessel. This is indeed amazing! As through my years of doing fermentation technology, there are many problems associated with the use of bioreactors or fermentors
There was no elaboration on the problems of sterilization, microbial contamination of the broth or cultures and how the process of inoculation, monitoring of the fermentation or the media used to support the growth of the plant tissues
The points raised are:
1 is the culture vessel autoclaved and can it withstand the repeated autoclaving as the vessel is made of glass
2Will continuous exposure of the vessel result in microbial growth that is photosynthetic?
3 How are the aseptic transfers and inoculation of the vessel carried out?
4 What is the likelihood of contaminations in such vessels?
5 Is the aseptic condition stringent throughout the period of growth?


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BIOMALAYSIA2011- A PERSONAL VIEW

It’s that time of the year again, when Malaysia showcases its ‘achievements’ in biotechnology. And it seems that this year event is no better than the previous similar events. A lot of hypes, great booths, smart name tags and a lot of hot air. It lacks the presence of renowned international biotechnology experts but overflow with relatively unknown speakers who seem to be keener in ‘advertising’ or ‘marketing’ their companies or products
On the local scene, the speakers or chair persons are more known as heads of departments rather than respected authorities in their own field in biotechnology. I don’t know whether this is more public relation exercise in buttering up certain departments or ministries in the government or its acceptance of the invitation to improve their CV
I have found the titles of the paper presented generally as ‘feel good ‘ papers laced with promises, potentials and not discussing problems and barriers that will be barriers to the commercialization.
It is interesting in this note that Kevin Keebung Rhee in his paper “From Bio Facility to Production” brought out the problems that will be faced in realizing these biotechnological dreams or endeavours
In such important gatherings it is important that the credibility be established from presentations of serious scientific discoveries rather than repacking old wine in new bottles or giving stories from La La Land


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IMPROVING SHELF LIFE OF FERMENTED FOOD

It is funny to observe the human behavior. When we say it is FERMENTED food they are willing to consume it eagerly. Yet if we tell them the same food as DECOMPOSED food, they will probably ignore or reject it.
Face the fact, fermentation process is a natural decomposition process which occurs naturally. While it is true in certain ways it is food preservation, the process has to a degree involved decomposition or metabolic transformation
The food preservation aspect is the result of the fermented products such as lactic or acetic acid which prevents the growth of other microorganisms that may enhanced decomposition. Or it could be the effect of high salt which prevent the growth of the other organisms.
The ability to preserve the fermented food is one of the challenges in the fermentation food industries. Too short a shelf life will make it difficult to store the fermented food or limit its availability for safe human consumption.
In cases of certain fermented food attempts to improve the shelf life of the products usually require the manipulation of low temperature or refrigeration combined with high quality packaging. But then again such a system could at best slow down the process of food spoilage and extend to a limit the shelf life of the fermented food. A good case is in the production and transportation and storage of milk based fermented foods
In extending the shelf life of the fermented food is not so much the issue. What is important is that changes that occur with the extended shelf life should not affect the quality and presentation of the fermented products!
This is the problem of marketing fermented foods which limit the volume of its production and the area of its distribution
Modern fermented foods have heavy inputs from food engineering and technology. Ingredients and other additives are frequently added to improve the quality and shelf life of fermented products
But this is only applicable in modern food fermentation industries but not at the level of traditional or small scale food industries


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BEING CLEAN IS BEING SANITARY IN THE FERMENTATION INDUSTRIES

One of the greatest nightmares in the fermentation industries is the fear of microbial contamination outbreak. Such outbreaks will not only mean financial disasters due to the loss of product and costly fermentation media but also problems of disposing the contaminated fermentation media which are generally rich in nutrients and are very polluting. There is also the fear that the fermentation products not only resulted in decrease of volume and concentration but could be hazardous to human health! This might lead to liability cases which might run into millions of dollars! Its simply a lose – lose situation in microbial contamination strikes the fermentation plant!
Removing or reducing the number of unwanted microbes is a big issue. If you don’t remove the microorganisms it will affect the fermentation process. To make it even harder, all those residual nutrients could support the growth of the contaminating microorganisms. So the issue is not only removing the microbes but removing the remnant nutrients as well.
To clean and remove the offending microbes and nutrients we have to reach almost every surface, nook and cranny. This activity is not only restricted to the fermentor but all inlets leading to or from the fermentors. And this is not easy as it is difficult to reach those far reaching hidden places to effectively clean and sanitise the system. This problem is accentuated by poor design of the fermentation system which protects and even helps in the propagation of the contaminants.
We can look at the problem of fermentor sanitation from the point of:
1 Materials used for the fermentation system
2 Finishing of surfaces
3 Design of fermentation system
4 Sanitary fittings
The cleaning process is a harsh process in terms of the effect of the cleaning chemicals on the surfaces as well the effect of physical removal of dirt and slime from the fermentation surfaces. The materials used to build the fermentation system must be able to with stand the treatment.
Stainless steel is often the choice as not only its being inert and do not react with the cleaning chemicals but also with the fermentation process
The surface finish is of great importance. It is often said the smoother the surface the less chance for the contaminants to stick. This would make cleaning easier and efficient.
In reality if you look under microscope even the smoothest finishing is rough and provides refuge for the microbes to survive the cleaning surface. So even though smoother surface is better but it is not a guarantee.
What is more important is the cleanability or the ease of cleaning the surface for effective cleaning
The design of fermentor systems should not encourage the presence of inaccessible areas for microbes to survive and propagate. Dead legs or dead spaces should be eliminated or minimized. Threaded screws should be avoided as it could backfire in providing refuge instead of preventing the entry of microbes. Valves and pumps should be simple in design and easily disassembled for CIP procedures.
The cleaning of fermentation systems should be based more on the understanding of the behavior of the microbes and a more integrative holistic approach should help in maintaining sanitary conditions of fermentation system




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SYMBOLISM OF ISTANA LAMA SERI MENANTI

Most visitors coming for a visit to the Istana Lama seems to be unaware of the various symbolisms and culture associated with the Istana Lama. They come, take photographs and have a whirl wind tour of the Istana Lama which is now a museum and was before the King’s residence.
It is generally accepted that the design of the palace was based on 99 pillars which represents the famous warriors of the state and even the various districts of the state
Most were quite satisfied by just visiting the first floor or at most the second floor. There are very few information available, no pamphlets, no guides. It feels just like an ordinary boring visit, just old pictures that adorn the walls.
The centre piece of the visit seems to be the main dining table where the King used to have dinners or entertain guests and dignitaries.
If we analyse the structure and function of the Istana Lama, it shows a hierarchy in the vertical structure. You will see that the first floor is open to public where the King receives his guests or where there are official ceremonies in little halls.
The second floor is dedicated to the family of the King complete with separate bedrooms for their children
The third and the fourth floor are in fact just small room. The room on the third floor is meant for the private use of the King. More interesting is the fact the fourth floor room is above the third floor room which is above the King’s room.
What is the function of the top most room? It is given a special status to be even above the King’s room? Usually the King being the supreme head is symbolically given the highest or top most room.
The fourth floor room is officially stated as the place where they keep the ‘heritage treasures’ of the state. What heritage treasures?. It was even erroneously stated that the fourth floor room was the ‘study room’ for the ruler
Many would find it difficult to believe of the tales or stories associated with the fourth floor room. Many years ago we took the opportunity to see the room. We saw a bed in the corner of the room and an incense burner for burning the kemenyan. Legend has it though no one stays there, there were signs that the bed has been used nightly and that the bed is made up every day. The question who or what is sleeping on the bed? Definitely not the King as he stays most times in Seremban or in the modern big palace nearby
What is even more interesting is the design of the steps leading to the third floor room and the fourth floor room is very steep and narrow. Is the design of the steps made to prevent access to other members of the palace?





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SCALING UP EXERCISES- THE OBSESSION WITH HUGE FERMENTORS

Judging from the list of the most popular articles, the topics of scaling up and scaling down seems to be the most favoured among the readers. The only conclusions I can derived from such popularity is that either most readers do not know or the topics of scaling up or there is a lack of good books or courses on the topics.
In my opinion, not many practitioners are willing to share their experiences on scaling up and scaling down due to its huge practical importance in industrial fermentations. The understanding of scaling up and scaling down is derived more through trials and errors and earned the hardway that constitute valuable experience.
A brief perusal on the topic in biochemical engineering and biotechnology books are quite lightly covered. It is more a theoretical in approach and highlighting the importance of scale of size, volume magnitudes and sustaining in the constancy of values such as power, impeller speed and dissolved oxygen.
They never really teach you the right approach or the essential steps in doing scaling up. They are more obsessed with size and geometry of fermentors.
In reality the subject of scaling up is not straight and easy . There are many other factors specific to a particular fermentation studied. That is why you have to find your way in doing the scaling up. This can only be achieved if you have done extensive work on the fermentation process that will yield sufficient data to help plan the next step in the scaling up. These lab data are very useful in extrapolating the direction of your scaling up and determining the size and number of size increase you need to do
You cannot do scaling up just by dumping in fermentors of different size or with similar geometry.
That is why before you do scaling up, you need to know holistically the fermentation process in question. If you don’t do this approach it will just be a study in futility yielding data which are of no values in industrial fermentation


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THE PROBLEMS OF CLEANING INDUSTRIAL FERMENTATION SYSTEMS

One of the significant steps to prevent microbial contaminations in industrial fermentation systems is keeping the fermentation systems clean not only from the presence of residues of fermentation but from the presence of unwanted microorganisms.
Effective sterilizations could only be achieved by first cleaning the fermentation systems. Proper cleaning of the fermentation systems require in depth study and understanding the structure and behavior of the properties of the foulings
Only by understanding these prerequisites can you develop cleaning regimes which are specific to the process in mind. This will not only give you effective sterilizations but even save you money in terms of chemicals used in cleaning, lower labour costs and less downtime. It will also give you assurance that your fermentation processes will be free from contaminations
Cleaning the fermentation systems is not as easy as it looks. There are dirts and particles which you cannot see with your naked eyes. Seeing it is ‘clean’ does not always mean its really clean.
The problems faced in cleaning the fermentation systems are:
1 How to detect the biofoulings
2 Methods to detect presence of microbes or its by products on surfaces
3 Looking for inaccessible places where its difficult to remove them
4 Using the right cleaning technology
5 Validating that the cleaning process have been really carried out
In the fermentation industries we are dealing the problems of cleaning at the level of microscopic or nano level. Surfaces exposed to dirt and contaminants occur microscopic level. What appears as a smooth shiny surface could under microscopic observation be rough and craggy giving protection and attachment to the microbes. It is not easy to remove such hidden microbes in the conventional way
Mot of the biofoulings are biofilms which have thick exopolysaccharide to protect the cells. Thus using chemicals does not always guarantee the removal of the cells
Sometimes you need special tools to observe the fouling such as using lights of different wavelength that can detect proteins and other metabolites
The use of wrong biocide regime could instead of removing the biofilm cause it to produce thick biofilms. This is contrary to the purpose
Proper research need to be done at laboratory level to determine the right cleaning regime before the method is applied



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IMPLICATIONS OF BIOFOULING OF SURFACES IN FERMENTATION INDUSTRIES

In nature,microbes generally do not occur as individual independent cells. There is the tendency for the microbes to form colonies or aggregates. One form of microbial aggregates commonly found in nature and in fermentation industries are the formation of microbial film or biofoulings.
It is not difficult to understand why microbial films occur especially in systems which provide surfaces for the attachment of the microbes. Other requirements include the presence of water and nutrients. It is only a matter of time when fresh surfaces will be colonized by the microbes or the surfaces undergo biofoulings.
In the fermentation industries the above requirements are easily met. The fermentation systems have lots of surfaces to be colonized by the microbes ranging from the surfaces of fermentors to the various valves and pipes servicing the fermentor
The presence of these biofoulings can constitute serious problems that affect the efficiency of the fermentation industries such as:
1 Microbial induced corrosion, biofouling of probes, sensors and electrodes
2 Pipe cloggings resulting in reduce flow
3 Heat exchangers
4 Microbial contaminations of the fermentation process
5 Wear and tear of pumps
6 Higher energy usage and repairs
7 Loss if downtime of fermentors in repairing and cleaning the biofoulings
All of these factors contributing to increase in costs!!
Preventing and solving the problems of biofoulings in fermentation industries is therefore crucial to the fermentation process


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YET ANOTHER FERMENTATION TECHNOLOGY WORKSHOP?

My, oh my! The local universities are back again offering some sort of fermentation technology workshop. What attract me in the recent brochure is the workshop on fermentor design and scaling up to be carried over four days.
The syllabus is nothing new and in fact never really delves into the ‘twists and turns’ of scaling up studies. Or could I have misread it? Maybe it’s the kind of course for general laymen such as ‘Fermentation technology for Dummies’ series?
Scaling up is a very difficult component in any fermentation technology course ! You could not cover it in just a few hours.
Honestly I cant help feeling the possibility of the participants being taken for a ride.
The only good thing I see in the brochure is that it is dirt cheap, where you only pay about RM 200 per day which includes course materials. Laboratory and refreshments such as breakfasts and lunch.
The added bonus is perhaps you will get a certificate of attendance and a good holiday!
My best wishes to the participants and enjoy the holidays!


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THERE IS MORE TO SAMPLING THAN THAT MEETS THE EYE

In the field of fermentation technology, the importance of sampling of samples right from upstream to downstream activities could not be more emphasized. It is from the analyses and measurement of the samples obtained that we derived data or valuable information which tell us about the state of the fermentation process. These data helps us in making decision by analyzing and extrapolating. It might even tell us where, when and how problems developed in the fermentation systems
The processing of the data obtained could even be enhanced further by applying graphics, statistics to even modeling the system so that we will have full control of the fermentation process.
Despite such immense importance of the contribution of samples to the understanding of the process, the desired impact might be erroneous or even negated by not understanding the process of sampling completely.If not done properly any data obtained from the samples and sampling could lead to the wrong conclusions and wrong decisions. This does not even take into considerations the loss of time, money, labour of the company.
In many years of experience in teaching, research and consultations, it is sad for me to conclude that many if not most involved in the field of fermentation technology regarded sampling as a trivial activity and have that couldn’t careless attitude. Their ignorance and lack of understanding of the purpose and factors affecting the sampling process have resulted in the wrong data and wrong decisions that affect the company productivity and efficiency
Again, this might be a syndrome of fear of admitting self ignorance of the subject or being recalcitrant in trying to learn new things despite being expert in the field of fermentation technology
In most if not all fermentation technology courses or textbooks, references to sampling is so brief and too theoretical. Most just cover the definition or explanation of the characteristics of the different type of samplings from off line, on line and in line sampling. There is no real in depth discussion and limitations of good sampling. There is a lack of application of the subject and its importance.
Suffice to say, this has led to the weakness of the students or lack of appreciation of sampling in fermentation system. One good example not often covered is the reliability in sampling systems and analysers

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STEAMING IN PLACE (SIP)

One of the two most common terms used in fermentation technology or fermentation industries is SIP or Steaming In Place; the other term being CIP or Cleaning in Place. While the two terms are often used, many find its confusing in its applications.
CIP refers more to the cleaning, washing and removal of residues or products from the surfaces of the fermentation apparatus, while SIP refers more to the actual sterilization of the fermentor and its processes using steam. However SIP may have the added bonus of cleaning the process and may constitute as part of CIP
In both processes of SIP and CIP, the most common feature is that the two processes are often carried out with little or non dismantling of the fermentation system. It is a fact that it is not easy to dismantle the fermentation systems and then to put it all back again. Lots of labour, time and costs may be incurred in dismantling. However in terms of efficiency of cleaning and sterilization it is more thorough and efficient
Why SIP when you can sterilize using autoclaves? The answer is that the use of autoclaves is quite restricted in situation where the size of the fermentation system such as in industrial fermentation is too large. Using of hot dry steam in SIP sterilization is more efficient and convenient than autoclaves. You can transport and guide the hot steam even in the most difficult and inaccessible places such as piping and hard to reach areas.
Using steam is amenable to manipulation and not so much restricted by the limitation of surface area to volume of fermentors. A good example is in the frequent use of steam injection into the fermentation broth
In using steam as SIP component we need to know the properties of steam. This refers to the quality of steam. In certain situations the steam produced must be filtered with microfilter to ensure the entrance of unwanted particles, organic or inorganic! In such situation the boiler used to generate the steam for SIP must be dedicated
BOILERS TO PRODUCE STEAM
The steam must be produced using boilers and it is important to control the steam pressure by the use of valves, pressure gauges It is important too that the heat loss of steam must be minimized by proper piping
STEAM PIPINGS
The steam piping needs to be insulated and lagged with material. The cleanliness of the steam must be maintained by the use of proper material such as stainless steel or teflon

The transformation of the steam into its liquid condensate must be properly addressed. This is not easy as we must try to release the condensate without losing the hot steam
The piping must be able to withstand the harsh condition of steam pressure of about 20 psi and temperature of 121 -125 degrees centigrade
The presence of airlocks must be avoided. Since air is a poor conductor of heat, the presence of airlocks will reduce the efficiency of steam heating


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THE INDUSTRIAL BAPTISM OF FERMENTATION TECHNOLOGY GRADUATES

Most fermentation technology graduates are generally pissed off when in their first exposure as attachment students in fermentation industries they are asked to clean floors and fermentors. In their view such a job is so demeaning of their status. In the hierarchy of jobs in the fermentation industries, the job of a cleaner is often looked down upon.
Yet, it is in my opinion it is the most important and responsible job. Cleaning or sanitizing the fermentors or production floors is a very skilled and skilled job. Not only have they taught you discipline and hard work but also the start of understanding the industry from bottom up.
Cleaning the fermentor and the production floor is not identical as cleaning an office or some other janitorial jobs. You are not only trying to keep the place and equipments clean by being methodological and thorough but also in preventing contamination of the plant.
Poor cleaning or sanitizing can cost the fermentation industries great losses.
Once you are expert in cleaning you will begin to appreciate the asepticity of the system and also weak links in the route of the microbial contamination
So you should try to appreciate the opportunity of this ‘demeaning’ skill and do a good job at it!


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