Baker's Yeast Plants

Know-how and technology licensing.

Vogelbusch Baker's Yeast Technology

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

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.

1 blockdia bakersyeast
Process line

A complete yeast production line consists of custom equipment such as:

  • Molasses clarification line
  • Media preparation and sanitization line
  • Fermentation station with fermenters of different sizes
  • Biomass separators (nozzle type)
  • Filtration station
  • Extruders and packaging equipment
  • Yeast dryer
  • Utility stations

Waste water treatment is a necessity at most sites.

Carbon source
RAW MATERIAL PREPARATION

Molasses is clarified by sedimentation or mechanically, by separators, and sterilized with steam. Hydrolysates do not need any treatment but supplementation with nutrients, trace elements and vitamins.

The purified raw material is then mixed with nutrients in the fermenter.

AUXILIARIES PREPARATION

Auxiliary substances such as urea are dissolved, sulphuric acid is diluted to be ready for the process.

HefeSaccharomyces cerevisiae
Yeast strains

Selected strains of Saccharomyces cerevisiae which develop the high rising power needed for top quality are used for bakery products.

Our yeast culture collection contains hundreds of different baker’s yeast strains. Be it wet or active dry yeast, we have the right strain for each type of feedstock, meaning that you can switch to make the most of the current market situation.

Choosing the ideal yeast strain for your application is key to producing a leavening agent with superior performance.

1 yeast fermenter
Propagation of yeast
BIOREACTION

To start a new batch, a yeast inoculum is cultivated in the laboratory. The inoculum is used to seed a small fermenter with a capacity of 100 to 200 liters. The yeast from the latter is used to seed the next-largest fermenter until sufficient yeast has been produced to start fermentation in the production fermenter. This first batch, called seed yeast is separated in separators, washed and stored.

The seed yeast is used to start commercial yeast fermentations. One batch of seed yeast can be split into up to six portions, each of which are used to seed a commercial scale yeast fermentation process. When all seed yeast has been consumed, a new batch of seed yeast must be produced, starting with a fresh inoculum from the laboratory.

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), the wet yeast is processed in an extruder and carefully dried with hot air. A packing machine packs dried yeast 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 growth and yeast quality. Measures include balancing stress-related process conditions in the fermenter such as oxygen and nutrition supply, and pH and temperature control.

We pay close attention to process economics, with low energy and utility consumption, and high yields, to optimize the long-term cost-benefit ratio of the plant.

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 Co. - 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
DEUTSCHE HEFEWERKE (now OHLY) - Hamburg, Germany

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 and supply of key equipment (aeration) for an additional yeast fermenter. The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up was...

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

Fuel Ethanol Workshop 2017
12 May 2017

June 19-21, 2017 in Minneapolis, MN, USA

FAQ

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

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