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Nombre conferencia Aplicaciones industriales de la biocatálisisAplicaciones industriales de la biocatálisis               ...
Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization (Texti...
Aplicaciones industriales de la biocatálisis                      LEITAT’s Corporate presentation  OBJECTIVE        R+D+2I...
Aplicaciones industriales de la biocatálisis                      R+D+i market oriented services         1                ...
Aplicaciones industriales de la biocatálisisIndustrial Biotech:                                               Biocatalysis...
Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Indu...
PROCESS 1: Enzymatic fibre recovery and   Aplicaciones industriales de la biocatálisis  valorization from hempFIBNATEX is ...
Aplicaciones industriales de la biocatálisis Fibres separation process Traditional separation process:        1.     Culti...
Aplicaciones industriales de la biocatálisisProject substrates                                    Mechanically separated  ...
Aplicaciones industriales de la biocatálisis Enzymatic retting set up1. Enzymes:                                     3. Eq...
Diapositiva 10LU1         es una pectinase? o cel·lulasa???            Lenovo User; 11/09/2011
Aplicaciones industriales de la biocatálisisResults of the project                                        Fibers separatio...
Aplicaciones industriales de la biocatálisisResults of the projectFibers characterization:• Fibers fineness and yarn count...
Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Indu...
PROCESS 2: Enzymatic cotton processing   Aplicaciones industriales de la biocatálisisOBJETIVES:Substitution of conventiona...
Aplicaciones industriales de la biocatálisisProcess 2: chemical processingSTARTING FABRICSThe fabric used was a plain weav...
Aplicaciones industriales de la biocatálisis Process 2: Two step enzymatic process- Enzymatic desizing and scouring in sho...
Aplicaciones industriales de la biocatálisisProcess 2: One step preindustrial processSingle step continuous enzymatic proc...
Aplicaciones industriales de la biocatálisis    SEM ImagesA                                           B                   ...
Aplicaciones industriales de la biocatálisisTextile QualityQUALITY ASSESSMENT:- Desizing and scouring : iodine test and th...
Aplicaciones industriales de la biocatálisisReutilizations and SavingsALTERNATIVE SEMI-CONTINUOUS ENZYMATIC PROCESS Bath r...
Aplicaciones industriales de la biocatálisisIndustrialization and Tech TransferSATI, S.A. is devoted to:Design, weaving, d...
Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Indu...
Aplicaciones industriales de la biocatálisis Investigation in healthy ingredients and              food products          ...
Aplicaciones industriales de la biocatálisisSpecific objectiveA fat product with this solid fat content (SFC) profile and ...
PROCESS 3: Fats biocatálisis modification Aplicaciones industriales de la and oils                                        ...
PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis  3. Process optimization:                ...
PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis 5. RESULTS: 70:30 Fat:Oil E1 gives promis...
PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis    5. Characterization: Sample 70:30 Fat:...
Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Indu...
Aplicaciones industriales de la biocatálisisConclusions   1. Bioprocess industrialization in different sectors is a realit...
Aplicaciones industriales de la biocatálisisAcknowledgments                                               31
Aplicaciones industriales de la biocatálisis                       Thank you for your attention                           ...
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Anna Surribas - Aplicaciones industriales de la biocatálisis

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Aplicaciones industriales de la biocatálisis

Por Anna Surribas, Elena Genescà, Aleix Conesa, Roshan Paul, Marolda Brouta-Agnésa i Meritxell de la Varga.

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Transcript of "Anna Surribas - Aplicaciones industriales de la biocatálisis"

  1. 1. Nombre conferencia Aplicaciones industriales de la biocatálisisAplicaciones industriales de la biocatálisis Anna SurribasElena Genescà, Aleix Conesa, Roshan Paul, Marolda Brouta-Agnésa i Meritxell de la Varga. Barcelona, 16th November 2011 EL PARTNER TECNOLÓGICO
  2. 2. Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization (Textile sector)3. Industrial cotton processing (Textile sector)4. Fats and oils modification (Food sector)5. Concluding remarks
  3. 3. Aplicaciones industriales de la biocatálisis LEITAT’s Corporate presentation OBJECTIVE R+D+2I collaboration, adding technological value and a clear adaptation and evolution to the constant market changes. 1 2 3 4 (*) Images: applications of Leitat Technological Center to the FotCiencia’06, FotCiencia’07, FotCiencia’08 contests: 1.- Tineoella bisselliella larva adhered to a wool fiber 2.- Surface tension modified by plasma treatment in a textile surface 3- Poliamides (transversal section) 4- Scratch test of ABS (Acrilonitrilo, Butadieno, Estireno) 3
  4. 4. Aplicaciones industriales de la biocatálisis R+D+i market oriented services 1 2 3 4 4
  5. 5. Aplicaciones industriales de la biocatálisisIndustrial Biotech: BiocatalysisR & D in biotechnological solutions withapplication in industrial processes; applied Industrial Bioprocessesmicrobiology and microencapsulation. Bioproduct production Environmental Biotechnology Applied microbiology (process validation, biofilm models, strain isolation and characterization…) Microbiology testing Microencapsulation of antimicrobial products 5
  6. 6. Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Industrial cotton processing4. Fats and oils modification5. Concluding remarks
  7. 7. PROCESS 1: Enzymatic fibre recovery and Aplicaciones industriales de la biocatálisis valorization from hempFIBNATEX is a SUDOE (Sudoeste Europeo) project whose partners are: CITEVE (PT), IPN (PT), LEITAT (ES), ASINTEC (ES), ICAM (FR), GIH (FR) OBJECTIVES: – To create innovative textiles based on hemp natural fibers. – To develop a future market of hemp fibers. – Cover the whole process: from plant to product 7
  8. 8. Aplicaciones industriales de la biocatálisis Fibres separation process Traditional separation process: 1. Cultivation 2. Retting Cultivation 3. Drying 4. Separation and carding Water rettingConventional separation process: Chemical and mechanical process: Air drying 1. Breaking links between pectin/fibers and fibers/wood. 2. Use of chemicals (sodium Oven drying hydroxide). 3. High temperature process. Grinding (siglo XVIII) 8
  9. 9. Aplicaciones industriales de la biocatálisisProject substrates Mechanically separated Mechanically separated and fibers. chemically treated fibers.Skin separated from the 9wood.
  10. 10. Aplicaciones industriales de la biocatálisis Enzymatic retting set up1. Enzymes: 3. Equipment: Commercial enzymes Proveedor Texazym BFE (pectinase) Inotex Polygalacturonase Biocon Xylanase Biocon Scourzyme (pectinase) Color Center2. Process variables: Process variables LU1 Ugolini equipment Enzyme cocktail Process time Temperature pH Buffer / Chelant agent Agitation type Fiber polishing Agitated Incubator Bath/Fiber ratio 10
  11. 11. Diapositiva 10LU1 es una pectinase? o cel·lulasa??? Lenovo User; 11/09/2011
  12. 12. Aplicaciones industriales de la biocatálisisResults of the project Fibers separation with enzymes (P6): – Ecological separation process. – Low temperature process. – Short time process (catalyzing action of the enzyme). Fibers obtained with the enzymatic process (P6). 11
  13. 13. Aplicaciones industriales de la biocatálisisResults of the projectFibers characterization:• Fibers fineness and yarn count (microscope ZEISS Axioplan and the program Delta Pix 300).• Length of the fibers, individual measurements (UNE 40152).• Microscopic inspection (microscope ZEISS Axioplan and program Delta Pix 300).• Tensile strength (UNE EN ISO 5079).• SEM (Scanning Electron Microscope). Mechanically Mechanically Hemp skin fibers polished with treated fibers. treated and enzymes. enzymatic polishing of fibers. 12
  14. 14. Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Industrial cotton processing4. Fats and oils modification5. Concluding remarks
  15. 15. PROCESS 2: Enzymatic cotton processing Aplicaciones industriales de la biocatálisisOBJETIVES:Substitution of conventional cotton wet processing :(1) less harmful(2) less aggressive towards the environment and fibre(3) applied at mild conditions(4) cost-effective 14
  16. 16. Aplicaciones industriales de la biocatálisisProcess 2: chemical processingSTARTING FABRICSThe fabric used was a plain weave 100% cotton raw fabric.CONVENTIONAL CHEMICAL PROCESSChemical desizing, scouring and bleaching was carried out in a single bath with a final fabric rinsing.Cotton was thereafter dried and tested to assess the final quality. 15
  17. 17. Aplicaciones industriales de la biocatálisis Process 2: Two step enzymatic process- Enzymatic desizing and scouring in shortertime.- An alternative amylase and pululanase(Dextrozyme) for the desizing/scouring. Apectinase, humectant, chelating agent and bufferKH2PO4 are used.- Process conditions : 62ºC and 60 min at pH 4.1- Transfer to a second bath for chemicalbleaching. 16
  18. 18. Aplicaciones industriales de la biocatálisisProcess 2: One step preindustrial processSingle step continuous enzymatic process using thermoresistent enzymesOne step continuous process- Enzymatic desizing /scouring with acommercial thermostable amylase (TexazymeTA10)- Simultaneous chemical bleaching with H2O2- Process conditions : 105ºC during 60 min. 17
  19. 19. Aplicaciones industriales de la biocatálisis SEM ImagesA B C Scanning Electron Microscopy pictures of treated cotton fibres. (A)Chemical desizing, scouring and bleaching (B)Two step enzymatic process (C) One step continuous enzymatic processing 18
  20. 20. Aplicaciones industriales de la biocatálisisTextile QualityQUALITY ASSESSMENT:- Desizing and scouring : iodine test and the water penetration test (UNE EN 20811).- Bleaching: CIE whiteness using DATACOLOR spectrophotometer.- Weight loss and tensile properties of the fabrics (EN ISO 13934/1:1999) Whiteness Weight loss (CIE) Iodine test Drop test 15% 63,1 OK OK Conventional Treatment Enzymatic semicontinuous 11,75% 65 OK OK treatment Alternative enzymatic semicontinuous 13,37% 61 OK OK treatment Single step enzymatic 12,57% 71 OK OK process 19
  21. 21. Aplicaciones industriales de la biocatálisisReutilizations and SavingsALTERNATIVE SEMI-CONTINUOUS ENZYMATIC PROCESS Bath relation1:20. 10% amylase loss and 50% pectinase loss Bath loss around 20%. 3 bath reutilizations are possible due glucose formation causing textile yellowing.SINGLE STEP ENZYMATIC PROCESS Bath relation1:10. 90% amylase loss. Pectinase use is optional Bath loss around 20%. 4 bath reutilizations are possible. 20
  22. 22. Aplicaciones industriales de la biocatálisisIndustrialization and Tech TransferSATI, S.A. is devoted to:Design, weaving, dyeing, printing and finishing ofhome textiles, technical textiles for filtration andmedical textiles.SATI, S.A. has : 1. Scaled up the one step proces to a pilot plant autoclave level 2. Adjusted process parameters and compared other commercial enzymes Product Laboratory trials (CIE whiteness) Autoclave (CIE whiteness) Texazyme TA10L 72,9 58,2 Bialfa T 72,8 61,4 Aquazym SDL 69,3 57,1SATI, S.A. will ( 2011) : 1. Transfer the process to the continuous cotton processing industrial line. 21
  23. 23. Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Industrial cotton processing4. Fats and oils modification5. Concluding remarks
  24. 24. Aplicaciones industriales de la biocatálisis Investigation in healthy ingredients and food products 23
  25. 25. Aplicaciones industriales de la biocatálisisSpecific objectiveA fat product with this solid fat content (SFC) profile and better nutritional properties usingenzymatic interesterification. Processing temperature (20ºC) Mouth temperature (37ºC) 24
  26. 26. PROCESS 3: Fats biocatálisis modification Aplicaciones industriales de la and oils ENZYMATIC INTERESTERIFICATION2. FAT AND OIL SELECTION based on: 1. Composition (% of MUFA and PUFA) 2. Origin 3. Commercial availability 4. SFC 5. Economical aspects.Selected products: Vegetal fat with high melting temperature and good structural properties. Vegetal oil with a high percentage of PUFA and good SFC profiles in EIE reactions. 25
  27. 27. PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis 3. Process optimization: Variables Enzyme type and quantity Enzyme Characteristics Process time E1 Commercial Immobilized non-specific enzyme Temperature E2 Commercial immobilized specific enzyme Fat /oil ratio Agitation 4. Process conditions : Commercial immobilized lipase (E1,E2) Fat:oil ratio from 80:20 to 20:80 Initial N2 blanketing to avoid product oxidation. Process time 24h Temperature around 60ºC Agitation around 200rpm 26
  28. 28. PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis 5. RESULTS: 70:30 Fat:Oil E1 gives promising SFC results + good fatty acid composition 27
  29. 29. PROCESS 3: Fatslaand oils modification Aplicaciones industriales de biocatálisis 5. Characterization: Sample 70:30 Fat:Oil E1Differential scanning Calorimetry (DSC):- Crystallization starts around 22ºC- Two fusion ranges: higher and lower melting triglycerides.Slip melting point: SMP (ºC) 30,7 28
  30. 30. Aplicaciones industriales de la biocatálisisINDEX1. LEITAT presentation2. Enzymatic fibre recovery and valorization3. Industrial cotton processing4. Fats and oils modification5. Concluding remarks
  31. 31. Aplicaciones industriales de la biocatálisisConclusions 1. Bioprocess industrialization in different sectors is a reality although not common in Spain 2. After basic research, process optimization for industrialization must consider certain aspects: a. Costs b. Existing or required equipment c. Savings (energy, chemicals, water) 3. Raw materials, and specially enzyme sources, must be stable and reliable. 30
  32. 32. Aplicaciones industriales de la biocatálisisAcknowledgments 31
  33. 33. Aplicaciones industriales de la biocatálisis Thank you for your attention asurribas@leitat.org CENTRO TECNOLÓGICO DE LAS TECNOLOGÍAS DE LA PRODUCCIÓN

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