Fermentation in the Food Industry:
An Introduction to Biotechnology

Lynn Dokken, Biology Instructor, Montgomery, MN
Barry Schmidt, Agriculture Instructor, Montgomery, MN
Biotechnology Workshop, July 14, 1992
University of Wisconsin - River Falls

UPDATED JULY, 1995
Tim Buttles, Eau Claire North High School, Eau Claire, WI
Brenda Gilliland, Rapid City High School, Rapid City, SD
Rhett Hanson, Platteville High School, Platteville, WI
Cathee Pearson, Rutland School District, Rutland, SD


Table of Contents
  • Introduction
  • Description
  • Objectives
  • Timeline
  • Teacher Background
  • Laboratory Exercises
  • Evaluation Guidelines
  • National Standards
  • References

  • Introduction [top of page]

    In designing this project, one of the primary objectives is the creation of an activity that will have application in both Biology and Agriculture curricula. The activity can be incorporated into a Cell Biology Unit in Biology or Advanced Biology, into a Food Processing Unit in Agriculture, or as a Fermentation Unit in Biotechnology. The intent is to use this activity as an introduction to fermentation and will be followed by the introduction of some modern techniques and applications of biotechnology.

    This unit is designed so that the individual teacher can easily make modifications according to:
    Before beginning this unit, students are expected to have experience in basic lab procedures, lab safety procedures, library research skills, oral presentation skills, and class journal expectations.


    Description [top of page]

    This activity will introduce the students to fermentation as well as provide hands on experience with a variety of food fermentation processes. In this exercise, students will study fermentation as a natural biological process and also its implications in the food and agricultural industries. Included in this exercise will be laboratory activities designed to explore the production of everyday foods which are produced by fermentation processes.

    Students will be choosing a group fermentation project which will include an inquiry based lab, a personal journal, and a presentation based on their lab results and research. In addition to the project students will be exposed to the history, chemistry, economics, culture, and careers associated with fermentation. Because of its importance in the food industry, food safety information and activities will be shared with the students.


    Objectives [top of page]

    A. Teacher's Objectives: In the presentation of this unit the teacher will: 1. determine the level of instruction appropriate for student assimilation

    2. determine the amount of information appropriate for student assimilation

    3. instruct students in laboratory protocol relevant to this exercise

    4. evaluate student objectives

    5. integrate the activity with appropriate curricula

    6. facilitate discussion and student involvement

    7. learn and follow all food safety guidelines in the classroom

    8. meet National Science Education Standards for content, assessment, and program, Benchmarks for Science Education, National Resource Council recommendations for agricultural education, and the School-to-Work Initiative
    B. Student Objectives: At the completion of this activity the students will be able to: 1. explain fermentation in its general form

    2. define respiration in words

    3. write the formula for respiration

    4. contrast aerobic and anaerobic respiration

    5. identify 3 types of microorganisms which are used in food production

    6. list and describe the processes used to produce several fermented foods

    7. identify ways that biotechnology may be used to improve our food and food supply

    8. maintain a journal comprised of daily observations, reactions, activities, self observations and peer observations.

    9. demonstrate proper food safety techniques.

    10. observe, record, and analyze student generated data.

    11. coordinate lab and research data into a coherent presentation.

    Timeline [top of page]

    The following outline is a sample designed for classes that are approximately fifty minutes in length. If your class period is shorter or longer than this, you may need to change this schedule. The assumption is that the students have already worked in the laboratory setting and are familiar with procedure and aseptic techniques.

    The students in the class will be divided into groups of four or five. This grouping can be based on grade average, technique, appropriate behavior in the lab, and any other criteria the teacher is comfortable with. Each group will be responsible for one lab project (found at the end of the packet, or use your own). The fermentation of yeast lab (Day 6) can be done as a class laboratory experiment or a teacher demonstration.

    Suggestions have been made concerning videos, outside speakers, and field trips. The students will be expected to check the progress on their lab each day and record this information in their daily journal (discussed later in the packet.)

    Day Activities

    Day 1
    Day 2
    Day 3
    Day 4
    Day 5
    Day 6
    Day 7
    Day 8
    Day 9
    Day 10
    Day 11
    Day 12
    Day 13
    Day 14
    Day 15

    Teacher Background [top of page]

    History of Fermentation

    The use of natural biological processes to obtain useable products is certainly not new. Since recorded history, microbes have been involved in the preparation and processing of items in the daily diet of humans.

    Lacking any knowledge of microorganisms, or of ways in which contamination of food by them could be avoided, man learned to live with microbially infected foods. Usually the actions of these microbes ultimately made the food unacceptable, either by altering the appearance or odor of the food to a point which it was no longer appetizing or by producing poisonous toxins, some of which were lethal. Occasionally, however, microbial infections of food materials made it appear more appetizing and the taste enhanced. Ultimately, microbial infections of these foods were exploited, so the fermented foods and beverages now form a large and important sector of the food industry. Today the main groups of microbes involved in the industry include the yeasts, molds, and bacteria.

    Nobody knows exactly when cheese making began, but legend generally has it that its origin lies in the Middle East. A Bedouin, preparing for a journey across the desert, filled his skin pouch with ewe's milk for refreshment along the way. After hours in the hot sun, and weary from the jostling ride on the camel, the Bedouin opened the pouch made from the dried stomach of a sheep only to discover that the rich milk was no more. In its place lay a thin watery fluid surrounded by a thick white mass - whey and curds. Having nothing else to drink, he tried the liquid and found it tasted good; then he nibbled at the gummy curds and was equally pleased with the discovery. Arriving at his destination, he shared the remaining curds with his tribesmen, who were no less satisfied then he. Thus, quite by accident, cheese was introduced into man's diet. Today, the manufacture of cultured dairy products represents the second leading fermentation industry (next to alcoholic beverages), accounting for approximately 20% of all fermented foods produced world wide.

    While no such legend exists for the discovery of sauerkraut, it undoubtedly was also discovered by accident and trial and error methods.

    In the days before refrigeration facilities became available, a number of techniques were devised for preserving seasonally produced vegetables. One of the most efficient of these involved packing vegetables tightly in a vessel with salt or brine. This technique is thought to have originated in the Orient where, even today, it continues to be used extensively. Only in the last 60 years has it been shown that this method of preserving vegetables involves a microbiological fermentation.

    In cheese making, the mystery surrounding the nomad's discovery can be easily explained. The four essentials of cheese making were acting together that memorable day in the desert: milk plus a slight churning motion coupled with heat and rennet (the product of an enzyme produced in the membrane lining of ruminate animals stomach). The cheese discovered by the Bedouin was probably what we would call cottage cheese or cheese curds. Similar legends attend the origin of aging, curing or ripening which has lead to the many various cheese flavors we have today.

    We now know that in the production of sauerkraut, lactic acid bacteria proliferate in the brine. These bacteria produce acids which lower the pH. The combined action of the salt and acid lowers the activity of enzymes responsible for the breakdown of vegetable tissue. At the same time oxidative changes in the tissues are inhibited and thus prevent spoilage.

    Anaerobic Fermentation

    Although respiration and breathing are often thought of as the same, they are in fact two different processes. Breathing is the exchange of gases between an organism and its external environment. Respiration occurs within all living cells. Cellular respiration involves breaking the chemical bonds of organic molecules and releasing energy that can be used by the cells.


    enzymes
    ATP
     C6H12O6   +   6O2   ======>   6CO2   +   energy 

    Most students are not familiar with fermentation which occurs in some of the less complex organisms such as bacteria and yeasts. Fermentation reactions are anaerobic, proceeding without oxygen being present. Anaerobic reactions involve cellular food products and/or glucose sugar as their reactants. And without oxygen they can produce combinations of ethyl alcohol (C2H5OH), carbon dioxide (CO2), and lactic acid (C2H4OCOOH) as their products.

    We have used the products of anaerobic respiration (fermentation) to our advantage, supplying ourselves with food, drink, and even fuel for automobiles. Yeasts are used as tiny "fermentation factories" producing carbon dioxide and alcohol. Certain bacteria and molds ferment milk, producing carbon dioxide and lactic acid.

    It has been stated that the fermentations are the result of growth of bacteria, yeasts, molds, or combinations of these. Stated more precisely, the changes that occur are caused by the enzymes liberated by these microorganisms. Some foods usually said to be fermented are actually cured by the enzymes naturally inherent in the foods. Throughout the centuries fermentation has been one of the most important methods for preserving food; It still remains one of the most important methods. Relatively few people, however, are aware that the many food products consumed regularly are prepared and/or preserved by fermentation processes.

    It is essential to understand that the lactic acid bacteria produce acid which in effect inhibits the growth of many other organisms. Most species convert sugars to acids, alcohol, and carbon dioxide. The fermentative yeasts produce ethyl alcohol and carbon dioxide from sugars. They require oxygen for growth but not for fermentation. The molds have the greatest array of enzymes, are aerobic, and will grow on most foods to produce various types of digestion.

    The changes that occur during fermentation of foods are the result of the activity of enzymes. The enzymes arise from three sources: Those that are produced by the microorganisms that are involved in the fermentation, those that are native to the food, and those that are produced by the microbial flora that happen upon the unfermented food. A good fermentation is one in which the enzymes produced by the fermentative microorganisms play the primary role.

    There are relatively few pure culture fermentations. An organism that initiates a fermentation will develop until its byproducts of growth inhibit further growth and fermentation. During this initial growth period other organisms develop. They in turn are followed by other more tolerant species. This succession of growth of different species may be referred to as a natural sequence of growth. The use of starters or inocula should be based upon these facts. In general, growth will be initiated by bacteria, followed by yeasts and then molds, if conditions are suitable for growth of these microorganisms.

    Now let us try to relate these biological processes to biotechnology. What is biotechnology? "In the broadest and simplest terms, biotechnology is defined as the collection of industrial processes that involve the use of biological systems."(Harlander, 1991).

    We have been using bacteria, yeasts, and molds for centuries to produce a host of fermented foods including buttermilk, yogurt, sour cream, butter, cheese (over 700 kinds), pickles, sauerkraut, sausage, breads, crackers, pretzels, doughnuts, grape nuts (you thought it was a cereal brand name?), wines, beer, spirits, soy sauce, coffee, cacao, vanilla, tea, citron, ginger, and more.

    Biotechnology is also used in some food processing related areas including processing aids, ingredients, rapid detection systems, and biosensors. Enzymes acting as protein catalysts, are used extensively in the food processing industry to control texture, appearance, and nutritive value, and for the generation of desirable flavors and aromas. Because they are isolated from plants, animals, or microorganisms, their availability is dependent upon the availability of the source material. Using genetically engineered microorganisms for the production of enzymes eliminates the need to rely on source materials while ensuring a continuous supply of enzymes.(Harlander, 1991).

    The new technologies have allowed researchers to target the genetics of plants, animals, and microorganisms and to manipulate them to our food production advantage. What might be in store for tomorrow's food advancement? Predictions include:

    1. Environmentally hardy food-producing plants that are naturally resistant to pests and diseases and capable of growing under extreme conditions of temperature, moisture, and salinity.

    2. An array of fresh fruits and vegetables, with excellent flavor, appealing texture, and optimum nutritional content, that stay fresh for several weeks.

    3. Custom designed plants with defined structural and functional properties for specific food-processing applications.

    4. Cultures of microorganisms that are programmed to express or shut off certain genes at specific times during fermentation in response to environmental triggers.

    5. Strains engineered to serve as delivery systems for digestive enzymes for individuals with reduced digestive capacity.

    6. Cultures capable of implanting and surviving in the human gastrointestinal tract for delivery of antigens to stimulate the immune response or protect the gut from invasion by pathogenic organisms.

    7. Microbially derived, high-value, "natural" food ingredients with unique functional properties.

    8. Microsensors that accurately measure the physiological state of plants; temperature-abuse indicators for refrigerated foods; and shelf-life monitors built into food packages.

    9. On-line sensors that monitor fermentation processes or determine the concentration of nutrients throughout processing.

    10. Biotechnologically designed foods to supply nutritional needs; meat with reduced saturated fat, eggs with decreased levels of cholesterol, and milk with improved calcium bioavailability.(Harlander, 1991)

    Additional Information on Food Fermentations

    Sausage:

    1. Semi-dry fermented sausages

    2. Dry fermented sausages

    Lactic acid is produced, lowering the pH of the sausage to preserve and flavor.

    Enzymes:

    1. Chymosin
      Replaces rennet in over 80% of the cheese produced. Rennet is extracted from the stomachs of milk-fed veal calves. The supply is linked to the veal market, causing wide shifts in availability of the rennet.
      Recombinant Chymosin is produced by an E. coli. The gene for chymosin was transferred from a calf to E. coli.

    2. Amylase
      Amylase is the enzyme that will break starch into its separate glucose components. Amylase is used in the brewing industry for malting and used in baking.

    3. Glucose isomerase
      The enzyme glucose isomerase converts or isomerizes glucose (an aldehyde) to fructose (a ketone) which is a sweeter product. The fructose is 1.8 times sweeter than glucose, so less is needed for the same taste.

    4. Pectinase
      Pectinase is the enzyme that breaks down pectin, a polysaccharide found in fruit. Pectinase is used to remove particulate matter, or clarify, fruit juices.

    5. Glucose oxidase
      Glucose oxidase is an enzyme used in the production of dried egg whites. When drying egg whites the glucose present in the white can react with amines in a reaction known as Maillard browning. This will cause the dried egg whites to turn brown. The addition of glucose oxidase will bread down the glucose and prevent the glucose from reacting and causing the off color of the egg whites.

    To produce these recombinant enzymes, the gene is first transferred into bacteria. The bacteria are then grown in fermenters. The enzyme is purified and sold.

    Other additives:

    1. Commercial Gums: (Dextran, Gellan, Rhansan, and Welan)
      thickeners and stabilizers

    2. Xanthan gum
      Xanthan gum is a polysaccharide produced by the bacterium Xanthomonas campestris on the cell wall. Xanthomonas campestris occurs naturally on the leaves of plants in the cabbage family. Commercial xanthan gum is produced by aerobic submerged fermentation. The bacteria are mixed with sugar, a nitrogen source, trace elements, and other growth factors in a large stainless steel tank. During fermentation aeration, agitation, pH and temperature are precisely controlled. After fermentation the solution is pasteurized to kill all bacteria. The gum is used in many products including cakes, muffins, ice cream, sherbet, sour cream, salad dressings, sauces, gravies, syrups, and toppings. Taken from "Xanthan Gum, 5th Edition," by Kelco, 500 W. Madison, Suite 3180, Chicago, IL 60661, phone 1-800-535-2687.

    Diagram of respiration and fermentation

    CELLULAR
    ALCOHOLIC
    LACTIC ACID
     RESPIRATION 
     FERMENTATION 
     FERMENTATION 
     
    GLUCOSE
    GLUCOSE
    GLUCOSE
    |
    |
    |
    |
    |
    |
    V
    V
    V
    PYRUVIC ACID
    PYRUVIC ACID
    PYRUVIC ACID
    |
    |
    |
    |
    |
    |
    V
    V
    V
    CO2
    CO2
    LACTIC ACID
    +
    +
    +
    WATER
    ALCOHOL
    2 ATP
    +
    +
    38 ATP
    2 ATP


    Laboratory Exercises [top of page]

    Root Beer: [full lab procedure]

    Making Cheese: [full lab procedure]

    Kimchee: [full lab procedure]

    Sauerkraut: [full lab procedure]

    Fermenting Power of Bread Yeasts: [full lab procedure]

    Yogurt: [full lab procedure]

    Yeast Fermentation, Variation in CO2: [full lab procedure]

    Alternative labs:
    · "Dinner Date with a Microbe" by A. Gillen and R. Williams, The American Biology Teacher, May 1993, pages 268-274. Provides kitchen microbiology recipes and health information for yogurt, sauerkraut, and root beer.
    · Silos and Sauerkraut from The AgriScience Institute and Outreach Program published by the National Association of Biology Teachers, 1994, pages 5-1 to 5-28. Bottle biology labs for making mini silos and fermentation chambers.


    Evaluation Guidelines [top of page]

    Students will be evaluated on their daily journal writings, their lab techniques, the written presentation, and the oral presentation.


    Click below for copies of each form


    National Standards [top of page]

    Standard Group Lab Daily Journal Group Presentation Food Safety Speaker Yeast Lab Anaerobic Respiration History Field Trip Case Study
    Benchmarks                  
    3A            
    X
    X
     
    10I        
    X
     
    X
       
    12D
    X
     
    X
               
    NSE Content Standards                  
    A
    X
                   
    B          
    X
         
    C          
    X
         
    F      
    X
           
    X
    G            
    X
       
    NSE Assessment Standards                  
    A
    X
    X
    X
               
    B
    X
    X
    X
               
    C    
    X
               
    NSE Program Standards                  
    B
    X
             
    X
     
    X
    NRC Ag. Ed. Recommendations                  
    Scientific Content
    X
     
    X
     
    X
    X
         
    School-to-Work                  
    Career Exploration
    X
       
    X
         
    X
     
    High Academic Content
    X
         
    X
    X
    X
       
    Descriptions of the individual standards:

    References [top of page]

    Biology, Visualizing Life--Teachers Resource Binder. Holt, Rhinehart and Winston, 1994.

    Biology, Visualizing Life. Holt, Rhinehart and Winston, 1994.

    Brock, Thomas D. and Michael T. Madigan (1988) Biology of Microorganisms, 5th Ed. Prentice Halls, Englewood Cliffs, New Jersey.

    Coghlan, Andy. "An Explosive Start To Fast Maturing Cheese." New Scientist, March 16, 1991.

    "Fermentation;" Modern Biology Laboratories, Holt, Rhinehart and Winston, Investigation 7.2, p. 45-48.

    Frazier, William C., and Dennis C. Westhoff (1988) Food Microbiology 4th Ed., McGraw-Hill, New York

    Harlander, Susan K. "Biotechnology - A Means For Improving Our Food Supply." Food Technology, April, 1991.

    Harlander, Susan K. "Food Technology: Yesterday, Today and Tomorrow." Food Technology, September, 1989.

    Harley, J. and L. Prescott, Laboratory Exercises in Microbiology, William C. Brown Publishers, 1993.

    Heitel, Nancy, et al. "Production of Home Brewed Root Beer." Minnesota; Mankato State University, 1988.

    Lindquist, John (1990) Bacteriology 102 Lab Manual. University of Wisconsin-Madison.

    May, Ranee (1995) Special Topics in Food Science. University of Wisconsin-River Falls.

    Muriel Mandell, Simple Kitchen Experiments. Sterling Publishing Company, 1993.

    Oklahoma State University, Dr. Mary Grula, Fermenting Power of Bread Yeasts.

    Pearl, Anita May, Cuttle, Constance and Deskins, Barbara B. Completely Cheese, Jonathan David Publishers, Inc. Middle Villiage, New York, 1978.

    Pederson, Carl S. Microbiology of Food Fermentations. Westport, Connecticut; AVI Publishing Co, Inc., 1987.

    Potter, Norman N., and Joseph H. Hotchkiss (1995) Food Science, 5th Ed. Chapman and Hall, New York.

    Robinson, R.K. Ed. (1995) A Colour Guide to Cheese and Fermented Milks. Chapman and Hall, London.

    Rose, A.H., Fermented Foods, Academic Press, New York, New York, 1982.

    Towle, Albert, Modern Biology Holt, Rhinehart and Winston, New York, New York, 1989.

    Varnam, Alan H. and Jane P. Sutherland (1994) Milk and Milk Products. Chapman and Hall London.

    Wood, Brian J.B., Microbiology of Fermented Foods Vol. 1, Elsevier Applied Science Publishers, London and New York, 1985.


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