Biocatalysts builds intracellular enzyme production plant

Speciality enzyme manufacturer, Biocatalysts Ltd, has introduced an innovative production method to maximise the efficiency of intracellular enzyme manufacturing. This technology gives the company the technical capabilities to cost-effectively produce commercially viable intracellular enzymes at high yields.

Currently, the majority of enzymes that are available on the market are genetically modified secreted enzymes. This type of enzyme is easy to produce since the enzymes are stable outside the microorganism. The process involves a very large fermenter which in turn produces large quantities of enzymes. The separation of the enzyme is a simple process, using a centrifuge and ultrafiltration techniques, often followed by spray drying. These secreted type enzymes are primarily classed as commodities due to their large production quantities and low cost.

The 500L capacity fermenter

Four-step filtration

The new enzyme production plant will focus on manufacturing speciality intracellular enzymes. These are more difficult to produce due to the fact that after the fermentation the cells go through a cell breaker to release the enzyme. The quantity of microorganisms in the fermenter needs to be large so that a good yield of enzyme is produced, but once the cells have been broken, a viscous slurry is produced which is very difficult to process. For small- scale production in a laboratory this is possible using a high speed centrifuge, but when looking to scale up to commercial quantities this is practically impossible.

To overcome this problem, Biocatalysts worked on a four-step efficient filtration system which will separate the wanted enzymes out of the broken up microorganisms (sludge) at a fast pace so that no activity is lost. At the end the solution is bacto-filtered which ensures no H&S regulations are contravened by shipping products with live and viable GMOs in them. Overcoming this filtration barrier was a breakthrough for Biocatalysts and has allowed them to progress with the production of their innovative production plant. The new facility can produce 10s of kgs of freeze dried enzyme per week and this can be further scaled up to produce 100kg batches of very high activity enzyme.

 Ni?os