The Bioprocess

Since we now know what direction we want to go with our bioprocess on a larger scale by incorporating a two stage process of fermentation and processing of the product that we came up with.

Our bioprocess will begin in a similar manner to the home fermentation, in which several glass vessels (5-7 litres) holding a 7-10% sugar solution and water kefir grains. Will have cloth over opening held down with elastic band keeping out contaminants while allowing the Carbon dioxide produced by the fermentation process to escape. The room in which this stage takes place will be monitored to be kept at an optimum temperature of 22oC for a period of 24-36 hours. Once the water has successfully been cultured the glass jars are brought to the bioreactor where the cultured water can be transfered into the bioreactor while using a non-metallic strainer to separate the grains allowing them to be reused in a fresh clean jar repeating the initial process. The used jar can be brought off to be cleaned and ready for re-use.

The next step begins when enough of the kefir water is built up in the bioreactor. The bioreactor cools the liquid down to 4oC to prevent excess microbial growth and Carbon dioxide build up (causes an off-flavour). Once cooled flavouring can be added (2% fruit juice concentrate) which will be homogenised throughout the liquid medium with a motorised impeller (set for 80 RPM) overnight as electricity cost rates are cheapest at night. One of the ancillaries in the bioreactor design includes a non-return valve to 'burp' allowing carbon dioxide build up to be released without letting any contaminants in, perfect for overnight operations. The product is then ready to be bottled and distributed.

Diagram of Bioprocess

So there it is, our bioprocess, an amalgamation of research, learning, experience, compromise, problem solving and innovation. Having gone through the process I now realise how unique our process is and think we can be proud of how it has turned out with us taking advantage of our past experiences of home brewing, work experience, problem solving and overall team work to create a process that I feel ticks all the boxes. I feel that our process is very simple but that does not mean it's a bad thing, simplicity is key to functionality, the less complex the less that can go wrong. The simple process should be easier to explain in our teaching class which is a big plus. Furthermore I now realise that my ability to think outside the box has improved a lot.