dsm food specialties’ ingredients add · 2010. 7. 12. · dsm melamine dsm energy base chemicals...

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DSM Food Specialties

Enzyme formulations in the industrial fieldEnzyme formulations in the industrial field

From past to presentDr. Ir. Gabrie M.H. Meesters

Gabrie Meesters


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DSM Organizational ChartDSM Organizational Chart

DSM Innovation CenterDSM Innovation Center Corporate StaffCorporate Staff

Shared Competences &Business Support


DSM Nutritional Products


DSM Resins

DSM Engineering Plastics- DSM Dyneema

DSM Elastomers

DSM Agro

DSM Melamine

DSM Fibre IntermediatesDSM Special Products

DSM PharmaceuticalProducts

DSM Anti-Infectives

DSM Energy

DSM Nutritional Products• Human Nutrition and Health• Animal Nutrition and Health


Nutrition

DSM PharmaceuticalProducts

DSM Anti-Infectives

Pharma

DSM Engineering Plastics

DSM Dyneema

DSM Resins

PerformanceMaterials

DSM Fibre Intermediates

PolymerIntermediates

DSM Agro

DSM Elastomers

DSM Melamine

DSM Energy

Base Chemicals& Materials

Corporate Staff


DSM Managing Board

DSM Innovation Center

March 2009


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FactsFacts of theof the foodfood activitiesactivities

• DSM produces >50% of all vitamins in the world• Our products can be found in all kinds of personal care

products like (anti-wrinkle) crèmes, shampoos, sun blocketc.

• DSM makes ALL ingredients for cheese, except the milk• The top athletes of The Netherlands (soccer, hockey,

swimming, rowing, tri-athletes) use our PeptoProrecovery drink


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DSM Food SpecialtiesDSM Food Specialties’’ ingredients addingredients addquality to lifequality to life

Essential part of many every-day food & beverage products

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IntroductionIntroduction

• Since the early sixties, enzymes are produced for industrialpurposes.

• Especially in the solid formulations a lot of developmentshave taken place

• Leading in research are psd, dust formation, stability,solubility, application performance, compatibility, enzymeactivity


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What are enzymesWhat are enzymes

• Enzymes are proteins• Enzymes are bio-catalysts• Enzymes are used in all living organisms• Enzymes can be used in industrial surroundings• We modify micro-organisms to produce these enzymes in

large quantities• World market is about US$ 4 billion and growing ~5%

annually


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Per cell 200.000 – 500.000 !

1 nanometer (0,000001 mm)

How big are enzymes?How big are enzymes?


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Industrial enzymesIndustrial enzymes

• Enzymes for detergents• Enzymes for starch producing industries• Enzymes for baking• Enzymes for feed boosters• Enzymes for beverages, wines and beer applications• Enzymes for dairy industries• Enzymes for organic modifications and chemical processes

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Current production processesCurrent production processes

• Spray drying; esp.. in food and feed. Too high risks• Spray drying agglomeration. Food and feed applications;

State of the art• High shear granulation• Fluid bed coating layering• Extrusion spheronisation• Immobilisation for liquid applications in reactors (Also cross

linked crystals)• Ion exchange columns


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Single stage spray dryerSingle stage spray dryer


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Integrated Spray Dryer (Integrated Spray Dryer (NiroNiro))


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MechanismMechanism

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MSDMSD--materialmaterial


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Mechanisms during high shearMechanisms during high sheargranulationgranulation


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Typical growthTypical growth behaviourbehaviour of mixerof mixeragglomeratorsagglomerators


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Rotating Drum AgglomerationRotating Drum Agglomeration

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LLöödigedige agglomeratoragglomerator


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LLöödigedige: Choppers and plough shares: Choppers and plough shares


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MechanismMechanism


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Typical high shear granulateTypical high shear granulate

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Fluidised bed granulationFluidised bed granulation


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mechanismmechanism


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Low pressure extrusionLow pressure extrusion

Bextruder Hosokawafor low pressure extrusionØ = 0,3 – 1,5 mm

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SpheronisationSpheronisation

BexrollerHosokawa

for spheronization


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MechanismMechanism


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Topics of DiscussionTopics of Discussion

• Formulations for the detergent industry• Formulations for the starch and glucose processing

industries• Formulations for the baking, beverages and dairy

industries• Formulations for the feed industries• Formulations for the chemical processes


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Detergent enzymes in the 1960Detergent enzymes in the 1960’’ss

• 60’s : Protease powder• end 60’s, severe allergic reaction and irritation• Collapse of the market to almost zero• Development of granules

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Early granule developments in the 1970Early granule developments in the 1970’’ss

• Gist-brocades: uncoated prills, later switching to coatedprills

• Novo-Nordisk: prills, switched to coated extrudates


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GistGist--brocadesbrocades--prillprill formulationformulation

Compounds of the prill formulation Wt %

Non-ionic or PEG 6000Soy oilTiO 2

BHTPVPCaSO 4

Enzym e powderBuilder, Na2SO 4

42-5610.60.11.5525, max17-63


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••NovoNovo--granulationgranulation

• Due to tighter dust restrictions Novo switched to high sheargranulation

• Granule-T concept was developed• Fibres are essential• Coated with PEG

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Novo granuleNovo granule--T formulationT formulation

C o m p o u n d s o f t h e e x t r u d a t ef o r m u la t i o n

W t %

E n z y m e p o w d e r o r l i q u idC e l l u l o s e f ib r e sW a t e rF i l l e rC o l o u r i n g a g e n t

5 - 9 02 - 4 01 0 , m a x .0 - 7 01 - 3


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Granulation in the 1980Granulation in the 1980’’ss

• Gist brocades develops its MOM-technology• Novo sticks to and improves its Granule-T concept• Showa-Denko develops similar process based on artificial

fibres• Solvay develops technology on basis of LP extrusion• Miles develops technology on basis of fluid bed

coating/layering


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GistGist--brocades MOMbrocades MOM--formulationformulation

C o m p o u n d s o f t h e M O M -f o r m u l a t i o n

W t %

M o d i f i e d s t a r c hE n z y m e p o w d e rS u g a rS o r b i t o lT i O 2G l y c e r i nP a r a f f i nL o r o l C - 1 8

4 52 01 664432


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Granulation in the 90Granulation in the 90’’ss

• Low enzyme dust levels (60ng/m3)• New enzymes in detergents• Henkel joins the field of enzyme producers, using HP-

extrusion• Novo sees limitations to amount of enzyme added to its

granules• Gb-prill formulation sees its end coming• Gb-MOM-technology not for 90’s

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Granulation in the 90Granulation in the 90’’sscontinuedcontinued

• Solvay extrudates see end coming (too high dust levels)• Gb develops a coating layering technique• Genencor International comes on the marked with new

formulation called Enzoguard®, based on fluid bedcoating/layering technology


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EnzoguardEnzoguard

• Solid core ……20-80%• PVA-layer ……. ~1%• Enzyme layer + PVA 0.1-20%• (NH4)2SO4 layer 10-30%• Polymer + pigment ..1-10%• Neodol coating 0.1-2%


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Fluid bed spray coating/layering (LA)Fluid bed spray coating/layering (LA)


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Business consolidation in the early 1990Business consolidation in the early 1990’’ss

• Genencor acquired Gist-brocades- and Solvay Industrialenzymes (~35% market share)

• Novo acquires Showa Denko industrial enzymes (~40%market share)

• Henkel remains to produce for captive use only (~10%market share)


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Enzyme formulations from the mid 1990Enzyme formulations from the mid 1990’’ss

• Novo: Granule TX• GCI: fluid bed coating layering• Henkel: HP-extrusion• Use of granules in automatic dish washing matrix (higher

pH)• Use of enzymes in tablets


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Current statusCurrent status

• Dust requirements are met by current producers, levelsdecrease

• Storage stability• Formulation compatibility• GCI introdusing a new matrix granule, using fluid bed

technology


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Formulations for the starch and glucoseFormulations for the starch and glucoseprocessing industriesprocessing industries

• Starch degrading enzymes• glucose isomerase• enzyme reactors operated at elevated temperatures (65º)• immobilised enzymes• Leading is cost and life time of formulated product


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Formulation development 70Formulation development 70’’ss--8080’’ss

• Novo developed a extrusion process, and cross linking• Gist-brocades developed a prilling in liquid process, and

cross linking• Miles developed a extrusion process, including cross

linking, using two cross linking agents


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Formulations in the 90Formulations in the 90’’ss

• Genencor acquired, Miles, Solvay and Gist-brocadesbusiness, making them the largest player

• Novo remained equal is size• Current formulations based on ion-exchange columns


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Future developmentsFuture developments

• Increase life time of enzymes• Increase reaction temperature• New better enzyme screening• Current ion exchange will be around for several years to

come

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Formulations for the baking, beverages andFormulations for the baking, beverages anddairy industriesdairy industries

• In baking enzymes are applied as powders or in breadimprovers

• Baking allergy is well known, has increased sinceintroducing enzymes

• In 80’s these enzymes were spray dried• Now advanced spray drying is used to agglomerate the

products


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Formulations for the baking, beverages andFormulations for the baking, beverages anddairy industries (cont.)dairy industries (cont.)

• bakers grade: 95%(w/w)<225 µm, less than 1%<63 um• Other grades: 100%(w/w)<1000 µm , less than 1%<63 um• These grades will produce enzyme dust• Dairy and beverages: spray drying changing to MSD,

mainly liquids are used.• Dosing in small quantities from sachets, tablets or boxes


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Baking formulation technologyBaking formulation technology


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• Cost is leading, but in baking enzyme dust will have to bereduced

• More fancy techniques for small granule coating will bedeveloped

• Stability is of little concern in this area

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BakingBaking enzymeenzyme examplesexamples


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Beverage EnzymesBeverage Enzymes

Retail

Grapes

JuiceConcentratesFruits

Grain

Wine

BeerAlcohol

Enzymes

Enzymes, Wine,Yeasts, Chemicals

Goals DSM Food Specialties, Beverage Ingredients :

Exploration of our capabilities in enzymes, yeast and fermentation in the beverage(wine, fruit, beer, alcohol) industry by innovation and market penetration.

Specialty ingredients and processing aids for thebeverage industry


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Formulations for the feed industriesFormulations for the feed industries

• New field of application• Natuphos® best know product• DSM-Food Specialties was largest player in this field,

followed by Novo• DSM divested their business due to acquisition of Roche

Vitamins& Fine Chem.• Formulation recipe in relation to application is leading,

followed by dust reduction


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Feed formulation, BASFFeed formulation, BASF

Extrusion

Spheronisation

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ExtrudateExtrudate


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Feed applicationFeed application

• Enzyme granules are mixed with dry feed compounds,vitamins minerals etc.

• Steam injection to elevate (50-80ºC) temperature andincrease moisture content

• Pre-mix is pelletised using high pressures• Pellets are cooled down


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Current formulationsCurrent formulations

• Gist-brocades used spray drying in combination withmixing with inert

• DSM-FS uses low pressure extrusion combined with acoating

• Novo uses granule T process combined with additionalcoating

• Coatings stabilise product and reduce enzyme dustformation


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Formulation developmentsFormulation developments

• The combination of temperature and moisture is bad forenzyme stability

• Coatings need to prevent moisture uptake, but must allowdissolution of granules in stomach of animals

• Additives are added to increase stability

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• Better coating to increase pelleting stability from 60-80% to80-90 %

• lower dust formation• Enzyme stabilisation additives• New enzymes


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Formulations for the chemical processesFormulations for the chemical processes

• Chemical modifications of complex organic molecules• Stereo specific• “difficult” catalyst• Use in organic solvents is possible• Rapidly increasing marked


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Current formulationsCurrent formulations

• As a liquid (UF)• As a liquid, containing the micro-organisms• Immobilised in particles and cross-linked• Immobilised as enzyme crystals and cross linked (CLEC’s)


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• More types of enzymes will be used• Finding the right enzyme is the most important task

presently• In the case cost is important, immobilisation will take place• New immob techniques will be developed• CLEC’s seem not to have the potential to become big in

this field

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Enzyme forms in liquid phaseEnzyme forms in liquid phase

• Microbial stability• Lowering the water activity to levels where Aw<0.5 and or use anti-

microbial agents• Formulations based lowering water activity (Aw) by

• Salt addition + antimicrobial agent• Polyol addition (glycerol and or sorbitol)• Mixtures of salts and polyols

• Anti microbial agents used e.g. Na-benzoate, sorbate

• Enzyme stability


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Activity of antiActivity of anti--microbial agentsmicrobial agents

Figure 6; effect of the pH on the dissociation of benzoic (___) and sorbic (----) acid


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ConclusionsConclusions

• Use of enzyme applications is still growing• Different state of art per application field is seen• Enzymes for detergents are the best developed enzyme

products• Enzyme dust prevention in baking will be leading in this

field• In organic chemistry more enzymes are to be applied in the

near future


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We operate beyond the labels!We operate beyond the labels!

Yeast extract

Aroma’sYeast extract

Aspartame

Cultures

StarterCulturesRennets

AromasCoatings

Enzymes

Enzymes

YeastEnzymes

PUFA’s

ß-Carotene

dsm food specialties’ ingredients add · 2010. 7. 12. · dsm melamine dsm energy base chemicals...

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