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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