Baker's Yeast Plants

Know-how and technology licensing.

Vogelbusch Baker's Yeast Technology

As a leavening agent, yeast converts sugar in the dough to carbon dioxide. The dough rises because of the bubbles of carbon dioxide becoming trapped during baking.

With our technology, baker’s yeast can be produced from a variety of raw materials containing sugar or starch. Mixtures of cane and beet molasses are the best choice for top product quality. Owing to circumstances, the sugars from molasses may be replaced by other sugar sources, such as hydrolysates from starch or even stale bread.

Block diagram

Vogelbusch process of baker's yeast production

1 blockdia bakersyeastThe complete yeast production line comprises the following process groups:

  • Molasses storage
  • Molasses clarification line
  • Media preparation / auxiliary preparation
  • Fermentation station with fermenters of different size
  • Yeast separation
  • Yeast filtration
  • Packing machine for fresh yeast
  • Extruders and yeast dryer
  • CIP (Clean In Place) station
  • Utility stations for water, steam, blowers, instrument air, cooling water, a.s.o.

Additionally, waste water treatment is a necessity at most sites.

Carbon source
RAW MATERIAL PREPARATION

Molasses is purified either by sedimentation or by mechanical separation. The clarified molasses is sterilized and then mixed in the fermentors with nutrients, trace elements and vitamins or, in fed batch fermentation, slowly added as required.

AUXILIARIES PREPARATION

Auxiliaries such as urea, phosphate and magnesium salts are dissolved in tanks. Sulfuric acid and phosphoric acid are diluted and prepared for the various process steps.

HefeSaccharomyces cerevisiae
Yeast strains

Our yeast culture collection contains hundreds of different baker’s yeast strains. The most suitable yeasts are selected carefully from our strain collection to provide the best rising power for the respective raw material and application.

Choosing the ideal yeast strain is a prerequisite for baking yeast with high driving power and for a high quality product.

1 yeast fermenter
Propagation of yeast
BIOREACTION

The propagation of yeast passes through several stages. Yeast inoculum is cultivated in the laboratory. It is used to seed the pure culture fermenter. Via a pre-fermentation, the resulting yeast suspension is fed to the seed yeast fermenter. The seed yeast is separated and stored in a tank.

For commercial yeast production, the prepared fermenter is inoculated with a portion of seed yeast. After about 24 hours, the fermentation is completed and the yeast is separated off and washed.

Up to eight production fermentations can be started with one lot of seed yeast.

1 yeast drum filter
Final process steps
PRODUCT ISOLATION AND CONCENTRATION

Commercial yeast is separated from the fermentation broth by nozzle separators. It is washed with process water and filtered to increase the dry matter content of the resulting yeast cream.

For wet compressed yeast, the filtered yeast cream passes through an extruder, and is pressed and cut into wet yeast blocks. These are packed, and need to be cold stored until use.

To produce instant active dry yeast (iADY), it is first mixed with an emulsifier and pressed into fine strands in an extruder. The extruded yeast is carefully dried with hot air, transferred into silos and packaged airtight.

1 yeast iady
Product characteristics

Baker's yeast products manufactured with VOGELBUSCH technology have different characteristics:

 
wet yeast
iADY
Dry matter content (DMS)  28 to 34% 92 to 98%
Shelf live up to 4 weeks 2 years and more
Storage conditions  refrigerated room temperature
Design Focus

We design our plants to create the perfect environment for high yeast quality and yield.

Measures include a controlled addition of molasses, balanced oxygen and nutrition supply, efficient temperature control and an easy-to-clean plant design.

In order to optimize the long-term cost-benefit ratio of the plant, we pay close attention to process economics, with low energy and utility consumption, and high yields,  taking into account customer-specific requirements such as the local availability of water.

Proprietary equipment and apparatus

Vogelbusch equipment that can greatly enhance process efficiency includes:

Ultra-efficient fermenter aeration systems

The most suitable aeration system is chosen based on fermentor size, production capacity and available utilities. Three types of tried and tested industrial aeration systems are available for specialized applications.

More about  » Aeration systems

Alcohol sensors for process automation

Sensor-equipped analyzers continuously measure the alcohol concentration in the fermenting mash. Gas phase measurement using semiconductor sensors is normally recommended for baker's yeast, but liquid-phase measurement with custom retractable probes is also available.

More about  » Gas analyzers

CUSTOMIZED SOLUTIONS

Vogelbusch provides higly specialized services for yeast production plants including:

  • Feasibility studies to determine plant economics
  • Design, engineering and construction of production plants for fresh and dry yeast
  • Modernization and revamping of existing yeast production plants to increase capacity, improve yield and/or product quality, and save energy and water
  • Installation of complete or sectional process control systems
  • Upgrade of fresh yeast plants to iADY production

Our experts are also available for consultancy services such as strain supply and optimization, and laboratory and pilot plant testing.

Average consumption figures

Figures vary considerably depending on raw material, plant capacity and configuration as well as local conditions. To determine specific consumption figures, operating cost and investment cost, a feasibility study can be carried out for your particular case.

 

Our baker's yeast showcase projects

4 YeastConsulting
Yeast plant in Tashkent
CANDY GOLD - Tashkent, Uzbekistan

Following a feasibility study on the production of baker's yeast, the pre-engineering for a yeast plant designed for a daily capacity of 10,000 kg based on molasses was carried out in 2015.

4 YeastConsulting
Yeast plant in El-Harrach
CEGRO / AYS - El Harrach, Algeria

SGP Cegro on behalf of AYS Algerian Yeast Society in 2014 ordered a feasibility study to investigate the production of 10,000 tons per year of baker's yeast to be made from imported molasses.

4 SCY
Yeast plant in Ahvaz
RAZI YEAST & ALCOHOL COMPANY - Ahvaz, Iran

Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from cane molasses. Production in the yeast plant started in 2009, since manufacturing 32,000 kg per day of high quality instant active dry...

4 YeastAerator
Yeast fermenter in Hamburg
OHLY (Deutsche Hefewerke) - Hamburg, Deutschland

DHW of Hamburg decided to convert an existing fermenter to the Vogelbusch aeration system. The given situation required the redesign of the drive and included engineering and supply of the complete aerator system. The reconstructed fermenter has a capacity of 27,000 kg per day of baker’s yeast made from beet molasses....

4 DHWN
Yeast fermenter in Nuremberg
DEUTSCHE HEFEWERKE - Nuremberg, Germany

DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building. Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system including drive, mash pumps and heat exchangers). The fermenter is designed for 25,000 kg of baker's yeast per day made...

4 YeastFermenter
Yeast fermenter in Osaka
ORIENTAL YEAST - Osaka, Japan

To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering for an additional yeast fermenter and the supply of key equipment (aeration). The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up...

Process units

Find out more about the processes used in yeast production:

Treating of input materials for bioconversion.
Raw Material Preparation
Converting substrates by using micro-organisms.
Fermentation
Separating solid-liquid and liquid-liquid media.
Centrifugation
Concentrating products and treating effluents.
Evaporation
Separating suspended particles.
Filtration
Finishing of products and co-products.
Drying

News

Our Conference Schedule
20 Oct 2017

Check out below when and where you can talk to our experts over the next couple of months.

FAQ

All information given here is based on a standard process and can vary depending on plant configuration. For particular information please send us a message with your project details.

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