What Is Bioprocessing? The Importance of Microbiological Testing in Products Involving Microorganisms
Biotechnology is a discipline that combines biology and technology. This field is applied in various industries, such as food, agriculture, and medicine. Fermentation is one of the simplest biotechnology methods and has been used for hundreds of years.
In biochemistry and physiology, fermentation refers to living organisms, especially microbes that convert chemical compounds to produce energy. The biochemical reaction involved is the conversion of sugars into acids, gases, or alcohols. This sequence of reactions is known as a bioprocess.
From a chemical engineering perspective, fermentation is the process of cultivating large quantities of microorganisms and carrying out biotransformation inside specialized vessels called fermenters or bioreactors. These two pieces of equipment are essential for large-scale fermentation.
A fermenter is a closed vessel with sterile and controlled conditions used for fermentation. In this process, microbes are grown in a specific medium to produce various compounds. Meanwhile, a bioreactor is a closed vessel that uses living cells as biocatalysts, substances or living organisms that accelerate chemical reactions within biological systems.
Fermentation Stages (Upstream and Downstream)
The fermentation process consists of two major stages: upstream processing and downstream processing. These stages form a complete sequence that transforms raw materials into final products.
1. Upstream Processing
Upstream processing focuses on cultivating microorganisms or cells to produce the desired product. It includes three main components: microorganism preparation, fermentation medium preparation, and the fermentation process itself.
- Microorganism preparation involves selecting the appropriate microbe. In fermentation industries, bacteria and fungi are commonly used to produce specific compounds.
- Fermentation medium preparation involves creating the nutrient media required for microbial growth.
- The fermentation stage is where microbes grow in the medium and produce the desired product (such as organic acids, enzymes, alcohol, or antibiotics).
2. Downstream Processing
Downstream processing includes all steps performed after fermentation is completed and consists of three key stages: cell separation, cell disruption, and purification.
- Cell separation aims to isolate microbial cells or solids from the fermentation broth, typically using sedimentation, filtration, or centrifugation.
- Cell disruption aims to release intracellular products. This can be done using physical or chemical methods such as high-pressure homogenization, ultrasonication, thermal shock, osmotic shock, chemical extraction, or enzymatic extraction.
- Purification is necessary to ensure the final product has a high level of purity. Techniques include liquid extraction, sedimentation, HPLC, and membrane-based methods such as ultrafiltration. After purification and drying, the product crystallizes and becomes ready for use.
Applications of Bioprocessing in Industry
In industry, bioprocesses are used because they are more environmentally friendly, efficient, and capable of producing products that are difficult to synthesize using traditional chemical methods. Applications of bioprocessing extend across food, pharmaceuticals and healthcare, cosmetics, and material science/biofabrication.
In the food industry, many products we consume daily are the result of bioprocessing, such as bread, yogurt, cheese (using lactic acid bacteria), coffee and chocolate, as well as tempeh, tapai, soy sauce, and nata de coco (using Rhizopus, Saccharomyces, and Acetobacter).
In pharmaceuticals, bioprocessing is essential for producing medicines, vaccines, and health products. For example, fungal or bacterial fermentation produces penicillin and streptomycin for antibiotic manufacturing. Insulin can also be produced through microbial fermentation using E. coli.
In the cosmetic industry, many active ingredients are now produced using bioprocesses. A well-known example is hyaluronic acid, made through bacterial fermentation using Streptococcus or Bacillus. Other bioprocess-derived ingredients include niacinamide, peptides, and ceramides. These biotechnological ingredients are generally more stable, safe, and environmentally friendly.
In biofabrication and materials science, biotechnology is now being used to create eco-friendly materials. Examples include mycelium-based materials for packaging or leather alternatives. Additionally, microbial pigments are being developed as natural replacements for synthetic textile dyes.
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Why Can Fermentation Make Food Healthier? Let’s Take a Look through Microbiological Testing
Bioprocessing plays a major role in modern industries—from food, cosmetics, and pharmaceuticals to energy. By using cells, microbes, and enzymes, bioprocesses can produce cleaner, safer, more efficient, and more sustainable products.
In the development of products that go through fermentation processes or involve microorganisms, microbiological quality control is a critical aspect. The microorganisms used must be properly controlled, and the product must be free from unwanted microbial contamination to ensure safety and consistent quality.
This is where laboratory testing plays an essential role. Microbiological testing helps verify that the type and quantity of microorganisms meet established standards, while also detecting potential contamination at an early stage.
IML Testing and Research provides comprehensive, accurate, and reliable microbiological testing services for products that go through fermentation processes, as well as for food, cosmetic, and other products that require microbial testing before being placed on the market. Ensure your product’s safety and quality through appropriate laboratory testing.
Author: Safira
Editor: Sabilla Reza
Reference:
Shukla, S., Shukla, S., & Saini, R. (2023). Recent advances in fermentation technology. International Research Journal of Innovations in Engineering and Technology, 7(1), 1–6.
