industrial biotech in tienen - smart hub vlaams-brabant · 2017-11-07 · export of citric acid:...
TRANSCRIPT
Industrial Biotech
in Tienen
Hugo Bauweleers Flanders Investment and Trade Meeting,
Tienen, 16 september 2015
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Contents
1. The product and the market
2. CBT Key Figures
3. History
4. Biotechnological production
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Citric Acid
• Chemistry • Odourless, colourless natural product
• Distinctive acid taste
• Widely distributed in nature, biodegradable
• Acidulant • provides fruity tartness, complements fruit flavours • citric acid lowers pH, can act together with citric salts act as buffering
system • modifies sweetness
• Chelating agent • forms complexes with metal ions (e.g. calcium)
• Widespread uses • Nowadays most widely used organic acid in food
(E330 / FDA:GRAS), pharma, personal care and
industrial applications
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Applications & Uses (1)
• Food Beverages, jams, jellies, preserves,
candies, fats & oils, dairy products,
canned food, frozen food,
convenience food, meat products,
seafood,…
• Pharma Effervescent tablets / powders,
lozenges, anticoagulant solutions
(prevents blood clotting)
• Personal Care Body care products, hair care
formulas, dental care products, bath
& shower products
Typical usage level: 0,25%-0,40% in beverages
0,10%-3% in other food appl.
0,01%-3% typical;
higher as citrate-esters
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Applications & Uses (2)
• Detergents & Cleaners Dish washing, heavy duty laundry,
Industrial, institutional and
household cleaners
• Further Industrial Uses Metal cleaning & surface
treatment; Electroplating baths;
Construction industry; Textile
industry; Plastics industry
Typical usage level: dishwashing : mainly as the
sodiumsalt, up to 40%
surface cleaners : up to 12%
citric and 5% sodiumsalt
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Contents
1. The product and the market
2. CBT Key Figures
3. History
4. Biotechnological production
Markets: Applications:
Export of citric acid: >95%
Food 30%
Beverages 35%
Detergents + Cleaners
16%
Pharma + Cosmetics
19%
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Production capacity: 120 000 tons of citric acid (7,5% market share)
250 000 tons of co-products
Turnover: ~120-130 M€ Personnel: 295 FTE
CBT Key Figures
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Germany 18%
France 17%
US 7%
UK 10%
Ireland 9%
rest EU 32%
rest World 7%
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Contents
1. The product and the market
2. CBT Key Figures
3. History
4. Biotechnological production
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1916-1929 “R&D period”
• 1916 R&D at K.U.Leuven • Alphonse Cappuyns develops the
citric acid fermentation process using Citromyces
• Fermentation using pure sugar
• 1919 Foundation of “Les Produits Organiques de Tirlemont”
• Fermentation of sugars to organic acids
• Low yields
• Process problems
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1929-1977 “2 Generations of Growth”
• 1929 Foundation “La Citrique
Belge”, Italo-Belgian JV • Focus on citric acid with a new
organism: Aspergillus niger
• Combination of fermentation (B)
and DSP (I) know-how
• Price drop in 1934 from ~ 1 EUR/kg
to ~ 0.2 EUR/kg
• Hard struggle for the global market
share
• 1947 Citrique Belge becomes a fully Belgian company
• Start of ongoing growth
• Introduction of molasses as raw
material
• Start of byproduct valorization
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• Reorganisation and capital raises
• Improvements of productivity and quality
• Capacity increases: 43 112 kTUM
• 1997: Joint Venture in Wuxi, CN
• Improvements of productivity and stability
• Reorganisation and capital raise
• Capacity increase to 120 kTUM
• Closure of Chinese production site
• Investments in production
• Modernisation of organisation
• 1977 F. Hoffmann – La Roche A.G.
• 2003 DSM
• 2010 Adcuram AG
as of 1977: “Internationalisation”
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Contents
1. The product and the market
2. CBT Key Figures
3. History
4. Biotechnological production
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Industrial Biotechnology
• Fermentation
• Citric acid is produced by fermentation
(microbiological conversion using a mould)
from a carbohydrate (sugar, starch, grains)
• extraction from natural sources or
chemical synthesis are not cost
competitive
• Isolation & Purification
• Citric acid is isolated from the fermentation
broth using chemical reactions (with lime
and sulphuric acid)
• Purification is typically done by ion-
exchange, decoloration and crystallisation
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Microorganism
• R&D for strain improvement – Mutagenesis and selection of the best strains
– Selection tool: small scale lab fermentations
• Improvements – reduction of unwanted side products
– better temperature tolerance
– raw material flexibility
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Production Process
• Surface fermentation – on diluted molasses with nutrients
– dry spore inoculation with
Aspergillus niger
– Surface : 360.000 m²
– Cycle time ~ 8 days
– high yields
• Isolation & Purification – chemical reactions
– purification of citric acid solution
with ion exchange, activated
carbon, crystallisation
Sugar Citric acid
O2 CO2
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Commodity product
• Solid citric acid is typically available in • Paper bags – usually at 25 kg net
weight, about 30 to 40 bags stacked on
one pallet
• Big bags – from 500 kg to 1000 kg on
pallets (e.g. wooden CP1 or EUR)
• Bulk trucks
• Liquid citric acid is available in • Bulk trucks
• 1000 L IBCs on pallets
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Production Process
Input / Output Balance
238.287
103.213
50.101
19.043
111.837
52.433
53.520
97.874
26.560
Molasses
Sulfuric acid
Lime
Others
Citric Products
Citrocol
Syngenite
Mycelium
White Gypsum
Grey Gypsum C
op
ro
du
cts
CBT
Overall, about 18 000 truck loads / year
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