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ORIGINAL ARTICLE
Keywords Abstract
fermentation, metabolism, production,
sterilization, stress response, test method, Aims: To investigate the effect of molasses concentration, initial pH of molas-
waste water, yeasts. ses medium, and inoculum’s size to maximize ethanol and minimize methanol,
fusel alcohols, acetic acid and aldehydes in the fermentation mash in industrial
Correspondence fermentors.
Muhammad I. Rajoka, Industrial
Methods and Results: Initial studies to optimize temperature, nitrogen source,
Biotechnology Division, NIBGE, Faisalabad,
Pakistan. E-mail:
phosphorous source, sulfur supplement and minerals were performed. The essen-
muhammadibrahim_rajoka@yahoo.com tial nutrients were urea (2 kg in 60 m3), 0Æ5 l each of commercial phosphoric
acid and sulfuric acid (for pH control) added at the inoculum preparation stage
2007 ⁄ 1877: received 21 November 2007, only. Yields of ethanol, methanol, fusel alcohols, total acids and aldehydes per
revised and accepted 1 July 2008 100-l fermentation broth were monitored. Molasses at 29Brix (degree of dis-
solved sugars in water), initial pH 4Æ5, inoculum size 30% (v ⁄ v) and anaerobic
doi:10.1111/j.1472-765X.2008.02446.x
fermentation supported maximum ethanol (7Æ8%) with YP ⁄ S = 238 l ethanol per
tonne molasses (96Æ5% yield) (8Æ2% increase in yield), and had significantly lower
values of byproducts than those in control experiments.
Conclusions: Optimization of process variables resulted in higher ethanol yield
(8Æ2%) and reduced yield of methanol, fusel alcohols, acids and aldehydes.
Significance and Impact of the Study: More than 5% substrate is converted
into byproducts. Eliminating or reducing their formation can increase ethanol
yield by Saccharomyces cerevisiae, decrease the overall cost of fermentation pro-
cess and improve the quality of ethanol.
fermentation variables, sugar concentration, pH and yeast was 300 · 106 cell per ml was transferred to three
dosage (yeast cell inoculum), yield of product could be industrial fermentors of working capacity 300 m3 and
increased in favour of ethanol and byproducts could be fed with diluted molasses of different Brix or of
minimized. The present study deals with the optimization known Brix at the mash feeding rate of 15 m3 h)1
of process variables to lower the synthesis of byproducts (level of fermenter rise was 5% h)1). Addition of
and enhance ethanol formation during fermentation of molasses ended after 20 h. At this stage (called fermen-
molasses by the yeast S. cerevisiae in 300 m3 fermentor tation stage), no nutrient supplements were added.
and recovery of ethanol (95%) after distillation in indus- Only unused urea and phosphoric acid were sufficient
trial columns. to give the highest yield of ethanol (Dombek and In-
gram 1987). Fermentation temperature was maintained
at 30–32C by passing cooling water through plate heat
Materials and methods
exchangers. After additional 10 h (total time 30 h), fer-
mentation was complete and fermented mash from the
Substrate and nutrients
fermentors was transferred to still tank for distillation.
Carbohydrates in the molasses are readily available in
the form of fermentable sugars and need no pretreat-
ment (Murtagh 2003). Sugarcane blackstrap molasses Recovery of fusel alcohols
used was of production season 2004–2005 of Shakarganj
Fermented mash from the still tank was transferred to the
Mills, Jhang, located in the province of Punjab, Paki-
mash column (C-201) from top. Steam was applied from
stan. Molasses was diluted by mixing tap water in
bottom maintaining the temperature of bottom at 78–
60 m3 mild stainless steel tanks to attain desired Brix.
80C. Vacuum was applied through condensers. Vapours
Although molasses generally contain most of the nutri-
travelled from this column to condensers (E-205) where
ents required for fermentation, ammonium salts and
they heated the mash. From evaporator (E-205), vapours
phosphates are added to supply nitrogen and phospho-
passed to E-206A, condensate passed to column C-203
rus (Prescott and Dunn 2002). Commercially available
(called depuration column), where litter water from C-
urea (2 kg) and phosphoric acid (500 ml), previously
204 was also mixed. From C-203 mash was fed to column
optimized as described earlier (Borzani 1996; de Va-
C-204 (rectification column). Rectification of ethanol was
sconcelos et al. 2004), were used as the main nitrogen
done in range of 96Æ0–96Æ4%. This column was operated
and phosphorus sources in inoculum preparation stage.
under pressure and high temperature. From the bottom
Sulfuric acid was used to adjust the pH and as a sulfur
of this column, higher alcohols (fusel alcohols) and acids
source (de Vasconcelos et al. 2004).
were removed and quantified as desired.
Table 1 Effect of molasses medium Brix (initial pH 4Æ5) on production of ethanol, methanol, acetic acid, fusel alcohols and aldehyde in 300 m3
fermentors using 10% inoculum size at 30C
25 7Æ27 ± 0Æ31d (218d) 3Æ85 ± 0Æ42abc 0Æ56 ± 0Æ06b 0Æ25 ± 0Æ02d 22Æ6 ± 3Æ2a
26 7Æ15 ± 0Æ24d (216e) 4Æ01 ± 0Æ34a 0Æ57 ± 0Æ5a 0Æ32 ± 0Æ02b 19Æ1 ± 1Æ14b
27 7Æ47 ± 0Æ04c (225c) 3Æ89 ± 0Æ07ab 0Æ58 ± 0Æ01a 0Æ37 ± 0Æ02a 19 ± 0Æ7b
28 7Æ6 ± 2Æ21b (229b) 3Æ52 ± 0Æ047bc 0Æ54 ± 0Æ03c 0Æ29 ± 0Æ02c 18Æ2 ± 1Æ62c
29 7Æ7 ± 0Æ3a (232a) 3Æ34 ± 0Æ38c 0Æ46 ± 0Æ03d 0Æ23 ± 0Æ02c 14Æ6 ± 0Æ47d
F (P £ 0Æ05) 13Æ1 7Æ47 18Æ32 922Æ37 24Æ38
P 0Æ0014 (0Æ0000) 0Æ0083 0Æ0004 0Æ0000 0Æ0002
Each value is a mean of three runs. ±stands for standard deviation among three replicates. Values in parentheses are alcohol yield in l t)1 molas-
ses. Means followed by different letters differ significantly at P £ 0Æ05. F and P values indicated that influence of treatments on all attributes was
highly significant. Aldehydes were determined using potassium permanganate test time (PTT) in minutes.
Table 2 Dependence of formation of ethanol, methanol, acetic acid, fusel alcohols and aldehydes on pH of the molasses medium of 29Brix at
30C under nonaerated condition
Medium pH Ethanol (%) Methanol (g per 100 l) Acetic acid (g per 100 l) Fusel alcohol (g per 100 l) Aldehydes (min)
a ab c b
4Æ5 7Æ72 ± 0Æ32 3Æ65 ± 0Æ34 0Æ52 ± 0Æ03 0Æ23 ± 0Æ03 19Æ6 ± 2Æ4b
4Æ7 7Æ31 ± 0Æ32b 3Æ87 ± 0Æ43a 0Æ54 ± 0Æ06b 0Æ32 ± 0Æ04a 23Æ1 ± 3Æ04a
4Æ9 6Æ48 ± 0Æ04d 3Æ54 ± 0Æ33abc 0Æ58 ± 0Æ01a 0Æ34 ± 0Æ03a 19 ± 0Æ7b
5Æ1 6Æ7 ± 0Æ18c 3Æ46 ± 0Æ62bc 0Æ54 ± 0Æ03c 0Æ33 ± 0Æ02a 19Æ0 ± 2Æ23b
5Æ3 6Æ31 ± 0Æ3d 3Æ22 ± 0Æ11c 0Æ58 ± 0Æ01a 0Æ33 ± 0Æ03a 19Æ8 ± 2Æ33b
F (P £ 0Æ05) 75Æ66 5Æ24 5Æ14 76Æ00 12Æ13
P 0Æ0000 0Æ0227 0Æ0238 0Æ0000 0Æ0018
Each value is a mean of three runs. ±stands for standard deviation among three replicates. Means followed by different letters differ significantly
at P £ 0Æ05. F and P values indicated that influence of treatments on all attributes was highly significant. Aldehydes were determined using potas-
sium permanganate test time (PTT) in minutes.
Table 3 Inoculum size-dependent production of ethanol, methanol, acetic acid, fusel alcohols and aldehyde concentrations following fermenta-
tion of molasses medium of 29Brix (initial pH 4Æ5) at 30C under nonaerated condition
Inoculum size (%) Ethanol (%) Methanol (g per 100 l) Acetic acid (g per 100 l) Fusel alcohol (g per 100 l) Aldehydes (min)
a a c b
20 7Æ25 ± 0Æ28 3Æ85 ± 0Æ42 0Æ56 ± 0Æ05 0Æ35 ± 0Æ02 252Æ5 ± 3Æ5a
25 7Æ06 ± 0Æ19c 3Æ77 ± 0Æ39ab 0Æ56 ± 0Æ03a 0Æ42 ± 0Æ01a 18Æ87 ± 1Æ26b
30 7Æ8 ± 0Æ26a 3Æ66 ± 0Æ1b 0Æ53 ± 0Æ03b 0Æ30 ± 0Æ01a 15Æ25 ± 1Æ08c
F (P £ 0Æ05) 198Æ4 8Æ7 6Æ75 141Æ14 21Æ92
P 0Æ0001 0Æ0484 0Æ05228 0Æ0002 0Æ0082
Each value is a mean of three runs. ±stands for standard deviation among three replicates. Means followed by different letters differ significantly
at P £ 0Æ05. Aldehydes were determined using potassium permanganate test time (PTT) in minutes.
F and P at P £ 0Æ05) indicated that the effect of inoculum size on all (except acids) was highly significant.
changes in pH may affect cellular ionic equilibrium and The higher concentration of byproducts in the cells
metabolic enzymes that are particularly sensitive to such may enhance turgor if not effectively exported from the
variations (Munene et al. 2002). Under normal fermenta- cell. The decrease of byproduct formation is an example
tion condition, the optimal pH range for the yeast is 4Æ5– of a metabolic adjustment by the cells to minimize energy
5Æ5. Variation in these values may influence the metabolic consumption during metabolism. It is expected that when
activities. Fermentation of medium at pH 4Æ5 gave maxi- the yields of methanol, acids, aldehydes and fusel alcohol
mum yield of ethanol at 234 l from 1000-kg molasses decrease, the metabolism must shift towards ethanol.
(results not shown) and supported lower values of acids. Data of Tables 1 and 2 were compared for ethanol
Acetic acid accumulation in the medium may change the yield (7Æ7 and 7Æ72%, respectively) using molasses of
pH gradient across the cell membrane down to a pH as 29Brix at initial pH 4Æ5 but different inoculum size (10%
low as 2Æ5. If the extracellular pH is decreased further, the and 30%, respectively). It revealed that increase in inocu-
difference between external and internal pH becomes too lum size although did not significantly increase ethanol
high, which results in acidification of the cytosol (Taher- yield, but decreased methanol, acetic acid and fusel alco-
zadeh 1999). The undissociated carboxylic acids can dif- hol in the fermentation mash and corroborated the find-
fuse through the cell membrane (Gottschalk 1987; ings of previous studies (Borzani 2006).
Verduyn et al. 1990). As the cells usually have a higher Productivity of ethanol is affected by both inoculum
intracellular pH than the medium (Dombek and Ingram size and mash feeding size (Carvalho et al. 2003). Carv-
1987), the undissociated acid is partly dissociated into alho et al. (2003) performed experiments in 14-l fermen-
acetate and hydrogen ions intracellularly. Therefore, the tor and could easily control mash-feeding rate with
intracellular pH is decreased and affects the ethanol yield. peristaltic pump, but our distilleries have a fixed mash-
It has been reported that acetic acid at a concentration as feeding rate, and this variable was kept constant in these
low as 0Æ5 g l)1 can inhibit yeast growth (Gottschalk studies. For known sugar concentration and mash-feeding
1987). Variation in pH affected aldehyde content in the size, the ethanol production may attain a maximum value
form of elevated pH values. and formation of byproducts the minimum values when
the yeast viable count in the inocula was 15 · 106 cells Gottschalk, G. (1987) Control of product formation in anaer-
per ml (Munene et al. 2002). Inoculum size (30%) gave obes. Dechema- Monographs 105, 43–53.
the highest ethanol yield but the lowest yield of methanol, Latif, F. and Rajoka, M.I. (2001) Production of ethanol and
acetic acid, fusel alcohols and aldehydes (Table 3), and xylitol from corncobs by yeasts. Bioresour Technol 77, 57–
confirmed the results of previous studies (Remiz et al. 63.
1999). Our current yield testifies that methanol, acids, fu- Munene, C.N., Kampen, W.H. and Njapau, H. (2002) Effects
sel alcohols and aldehyde yields decreased by 33%, 5Æ0%, of altering fermentation parameters on glycerol and bio-
16% and 28% under optimized conditions, respectively, ethanol production from cane molasses. J Science Food Ag-
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while ethanol yield increased by 8Æ2% at industrial scale
Murtagh, T.E. (2003) Molasses as a Feedstock for Alcohol Pro-
under such conditions.
duction. Wirchester, Virginia: Murtagh and associates.
Prescott, S.C. and Dunn, C.G. (2002) Industrial Microbiology,
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