In our previous blog article, we analyzed the importance of fermented foods for our health. In particular, we focused on the advantages they bring to the gut microbiota and the digestive system; we also saw how they strengthen the immune system and support the functioning of the cardiovascular system.
In this case study, we want to explore the topic further by showing the process behind the formulation of new functional foods obtained through fermentation.
Starting Situation and Final Objective
Consumer interest in healthy eating and foods that ensure well-being and reduce the risk of disease is constantly growing. This increased consumer demand is matched by a push from companies to develop ever-new functional foods.
But what is behind all this?
A very long process, often not feasible by the company alone, which therefore seeks support from industry professionals… from us!
Relying on our multidisciplinary expertise—in biology and nutrition, but above all in engineering—we set ourselves an ambitious goal:
to develop the entire fermentation process at laboratory scale, study and optimize it, and then follow its scale-up to pilot scale.
Adopted Strategies
Achieving the goals of our studies was essential; we did not want to betray our own expectations. After careful initial analyses to assess the project and its feasibility, we created a batch-type laboratory-scale plant with a capacity of one liter. The aim was to ferment under absolutely sterile conditions.
The plant was tested on food matrices of different types—both animal and plant origin—and viscosities, experimenting with suspensions at different solid percentages.
The process was constantly examined from the following perspectives:
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Microbiological, to verify—through plate seeding—both the growth of the microorganism of interest and any contaminations;
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Chemical, to monitor—using HPLC—the production of metabolites of interest such as lactic acid;
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Physical, to study viscosity changes during the process.
The main issues encountered concerned some contaminations resulting from the imperfect sealing of the plant, which did not guarantee full aseptic conditions. This criticality was promptly resolved by improving the reactor’s isolation from the external environment.
The fermentation process was optimized for parameters such as temperature, pH, and carbon substrate. Scale-up to pilot scale was performed, and the plant was tested with new fermentation trials to verify that scaling factors were respected.
Results Obtained
The design and optimization of this new fermentation process at laboratory scale ensured:
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Adequate mixing;
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Monitoring of temperature and pH;
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Proper control of temperature and pH;
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Design and development of a 200 L pilot-scale fermenter (support);
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Optimization of the fermentation process to achieve high microbial concentration and production of metabolites of interest;
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Efficient scale-up to pilot scale, with scaling factors respected.
Conclusions
This experience was one of the first in which we actively collaborated with another company. Overall, we can consider it a positive and formative experience that allowed us to interface with new realities and laid the foundation for the multidisciplinarity that characterizes us.
