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Instant active dry bakers yeast is a well-known product widely used for leavening of bread, produced by fermentation,
and usually dried by hot air to 9496% dry matter content. Multi-stage uidized bed drying process is a commercial
effective method for yeast drying. In this work, optimum operating parameters of an industrial continuous uidized
bed dryer for the production of instant active dry yeast were investigated. The dryer contained four zones separated
with moving weirs. The operating conditions such as temperature, loading rate of compressed yeast granules, and
hot air humidity had direct effects on both yeast activity and viability. The most important factors that affected the
quality of the product were loading rate and the operational temperature in each zone on the bed. Optimization was
performed for three loading rates of the feed to the dryer, using response surface methodology for the experimental
design. The most signicant factor was shown to be the loading rate with mean fermentation activity values of 620,
652, and 646 cm3 CO2 /h for 300, 350, and 400 kg/h loading rates, respectively. The data analysis resulted in an optimal
operating point at a loading rate of 350 kg/h and temperatures of zones 1, 2, 3, and 4 controlled at 33, 31, 31, and 29 C,
respectively. The best activity value was predicted as 668 18 cm3 CO2 /h, and conrmation experiments resulted in
660 10 cm3 CO2 /h. At the same operating point, the average viability of the cells was predicted as 74.8 3.7% and
conrmed as 76.4 0.6%. Compared with the normal operating conditions at the plant, the optimization resulted in
more than 12% and 27% improvement in the yeast activity and viability, respectively.
2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
Keywords: Bakers yeast; Drying; Continuous uidized bed dryer; Optimization; Saccharomyces cerevisiae
1.
Introduction
Corresponding author at: Department of Chemical Engineering, Isfahan University of Technology, Isfahan 84156-83111, Iran.
Tel.: +98 3113915623; fax: +98 3113912677.
E-mail address: karimi@cc.iut.ac.ir (K. Karimi).
Received 12 April 2010; Received in revised form 24 November 2010; Accepted 23 December 2010
0960-3085/$ see front matter 2011 The Institution of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
doi:10.1016/j.fbp.2010.12.005
53
industries; in which uidized bed dryers with batch or continuous operations are widely used for industrial drying of bakers
yeast (Hovmand, 1995).
Bayrock and Ingledew (1997a) studied drying of compressed
S. cerevisiae in uidized bed dryer as well as its exposure
to moist heat in classical thermal death time experiments.
They reported that dehydration (not moist heat, dry heat, or
oxidation) was responsible for viability decreases during the
uidized bed drying. It was also determined that the viability
decreased sharply in the falling-rate drying period. Bayrock
and Ingledew (1997b) also studied the effects of moisture levels, drying rates, and yeast cell viabilities for two commercial
compressed bakers yeasts dried in a modied uidized bed
dryer. They found that death mechanisms for uidized bed
drying appear to be quite different from that reported for spray
drying.
The drying prole is extremely important in the drying process. Yuzgec et al. (2006) developed a non-linear predictive
control technique in order to determine the optimal drying
prole for a drying process in a batch uidized bed dryer. Simple drying models were also developed for industrial scale,
batch uidized bed drying of granular bakers yeast (Mustafa
et al., 2006; Hocalar et al., 2006). However, it is difcult to
develop an accurate model for the process. For a more predictive model, diffusive transport limitation of moisture inside
the granules should be considered. It requires mathematical
description of the distribution of moisture and temperature
inside the granules.
The purpose of this study was to maximize the activity
and viability of bakers yeast in an industrial continuous uidized bed dryer by optimization of its operational conditions.
The effects of yeast loading rate and temperatures of different
zones of the dryer were studied.
2.
2.1.
Outlet air
Zone 1 Zone 2
inlet
inlet
dryer air dryer air
Zone3
inlet
dryer air
Zone 4
inlet
dryer air
2.2.
2.3.
Experimental design
Area (m )
Inlet air temperature ( C)
Outlet air temperature ( C)
Inlet air ow (m3 /h)
Inlet yeast (D.S.%)
Outlet yeast (D.S.%)
Zone 1
Zone 2
Zone 3
Zone 4
2.8
100120
3234
24,000
3235
5060
2.8
80100
3133
22,000
5060
6575
3.6
6080
3032
21,000
6575
7785
4.4
4060
2931
20,000
7785
8892
54
Symbol
L
T1
T2
T3
T4
Level 1
300
34
33
32
31
Level 2
Level 3
350
33
32
31
30
400
32
31
30
29
T1
T2
T3
T4
Activity 1
(cm3 CO2 /h)
Activity 2
(cm3 CO2 /h)
Viability 1 (%)
Viability 2 (%)
300
300
300
350
350
350
400
400
400
300
300
300
350
350
350
400
400
400
34
33
32
34
33
32
34
33
32
34
33
32
34
33
32
34
33
32
33
32
31
33
32
31
32
31
33
31
33
32
32
31
33
31
33
32
32
31
30
31
30
32
32
31
30
30
32
31
30
32
31
31
30
32
31
30
29
30
29
31
29
31
30
30
29
31
31
30
29
29
31
30
570
610
640
640
680
660
640
670
620
640
600
650
650
660
650
660
630
630
600
590
650
620
670
650
650
660
630
620
620
650
630
680
640
670
640
650
59.9
66.35
67.88
72.84
75.51
73.39
73.94
73.85
69.9
70.86
73.21
67.98
71.03
74.13
73.85
72.51
72.12
72.96
60.24
66.11
68.42
72.26
76.59
72.81
73.64
74.73
68.74
72.74
72.43
66.88
69.77
75.47
74.55
73.21
71.38
71.42
1 and 2 indexes for activity and viability indicate the results for two separate replications.
2.4.
duced CO2 was recorded. The cell viability was measured using
the Methylene Blue dye staining method (Grifn et al., 2001).
All experiments were duplicated and one sample from each
experiment was collected and analyzed. The results shown
are the average of these duplications with a standard deviation of less than 4% for the yeast activities and 5% for their
viabilities.
3.
55
78
680
76
660
Activity (cm3 CO2/h)
74
Viability (%)
72
70
68
66
64
640
620
600
62
60
300
350
Loading rate (kg/h)
580
400
300
350
Loading rate (kg/h)
400
Coefcient
T-value
P-value
Constant
L
T1
T2
T3
T4
L*L
T1 * T1
T2 * T2
T3 * T3
T4 * T4
653.889
12.917
5.417
16.667
3.750
4.583
19.583
4.583
3.333
4.583
10.417
58.007
3.103
1.301
4.004
0.901
1.101
2.716
0.636
0.462
0.636
1.445
0.000
0.017
0.234
0.005
0.398
0.307
0.030
0.545
0.658
0.545
0.192
Parameter
L
T1
T2
T3
T4
Level
Loading rate
Zone 1 temperature
Zone 2 temperature
Zone 3 temperature
Zone 4 temperature
350
33
31
31
29
Table 4 ANOVA analysis of loading rate on average cell viability and activity.
Source
L
T1
T2
T3
T4
Error
Total
Degree of
Freedom
2
2
2
2
2
7
17
Viability
Activity
Sequential
sums of
squares
Adjusted
means
squares
F-value
P-value
Sequential
sums of
squares
Adjusted
means
squares
F-value
P-value
111.781
19.517
17.363
0.062
36.193
65.542
250.459
55.891
9.759
8.682
0.031
18.096
9.363
5.97
1.04
0.93
0.00
1.93
0.031
0.402
0.439
0.997
0.215
3536.1
436.1
3377.8
252.8
686.1
1455.6
9744.4
1768.1
218.1
1688.9
126.4
343.1
207.9
8.50
1.05
8.12
0.61
1.65
0.013
0.400
0.015
0.571
0.259
56
Table 7 Estimated regression coefcients for yeast activity and viability by full quadratic model.
Term
Activity
Coefcient
2995.28
4.94167
187.917
0.007833
3.333
0.0250
Constant
L
T2
L*L
T2 * T2
L * T2
Viability
T-value
P-value
Coefcient
T-value
P-value
81.063
2.920
3.768
2.556
0.435
0.231
0.000
0.013
0.003
0.025
0.671
0.821
254.477
0.9361
20.8750
0.0013833
0.294167
0.00245
43.775
2.516
1.298
2.176
0.185
0.109
0.000
0.027
0.219
0.050
0.856
0.915
D.S. (%)
Activity
(cm3 CO2 /h)
Viability (%)
1
2
3
4
54
72
84
90
470
555
600
660
95.82
87.41
80.73
76.4
These data are averages of four replications and the samples took
at the outlet of each zone.
(1)
4.
Conclusions
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