Baker's Yeast Plants

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Vogelbusch Baker's Yeast Technology

As a leavening agent, yeast converts sugar in the dough to carbon dioxide. The dough rises because of the bubbles of carbon dioxide becoming trapped during baking.

With our technology, baker’s yeast can be produced from a variety of raw materials containing sugar or starch. Mixtures of cane and beet molasses are the best choice for top product quality. Owing to circumstances, the sugars from molasses may be replaced by other sugar sources, such as hydrolysates from starch or even stale bread.

For key figures for yeast plant construction

CHECK OUT OUR » FAQ's

Block diagram

Vogelbusch process for baker's yeast production

The complete yeast production line comprises the following process groups

Molasses storage
Molasses clarification line
Media preparation / auxiliary preparation
Fermentation station with fermenters of different size
Yeast separation
Yeast filtration
Packing machine for fresh yeast
Extruders and yeast dryer
CIP (Clean In Place) station
Utility stations for water, steam, blowers, instrument air, cooling water, etc.

Additionally, waste water treatment is a necessity at most sites.

Carbon source

RAW MATERIAL PREPARATION

Molasses is purified either by sedimentation or by mechanical separation. The clarified molasses is sterilized and then mixed in the fermentors with nutrients, trace elements and vitamins or, in fed batch fermentation, slowly added as required.

AUXILIARIES PREPARATION

Auxiliaries such as urea, phosphate and magnesium salts are dissolved in tanks. Sulfuric acid and phosphoric acid are diluted and prepared for the various process steps.

Yeast strains

Our yeast culture collection contains hundreds of different baker’s yeast strains. The most suitable yeasts are selected carefully from our strain collection to provide the best rising power for the respective raw material and application.

Choosing the ideal yeast strain is a prerequisite for baking yeast with high driving power and for a high quality product.

Propagation of yeast

BIOREACTION

The propagation of yeast passes through several stages. Yeast inoculum is cultivated in the laboratory. It is used to seed the pure culture fermenter. Via a pre-fermentation, the resulting yeast suspension is fed to the seed yeast fermenter. The seed yeast is separated and stored in a tank.

For commercial yeast production, the prepared fermenter is inoculated with a portion of seed yeast. After about 24 hours, the fermentation is completed and the yeast is separated off and washed.

Up to eight production fermentations can be started with one lot of seed yeast.

Final process steps

PRODUCT ISOLATION AND CONCENTRATION

Commercial yeast is separated from the fermentation broth by nozzle separators. It is washed with process water and filtered to increase the dry matter content of the resulting yeast cream.

For wet compressed yeast, the filtered yeast cream passes through an extruder, and is pressed and cut into wet yeast blocks. These are packed, and need to be cold stored until use.

To produce instant active dry yeast (iADY), it is first mixed with an emulsifier and pressed into fine strands in an extruder. The extruded yeast is carefully dried with hot air, transferred into silos and packaged airtight.

Product characteristics

Baker's yeast products manufactured with Vogelbusch technology have different characteristics

	wet yeast	iADY
Dry matter content (DS)	28 to 34 %	92 to 98 %
Shelf live	up to 4 weeks	2 years and more
Storage conditions	refrigerated	room temperature

Design Focus

We design our plants to create the perfect environment for high yeast quality and yield.

Measures include a controlled addition of molasses, balanced oxygen and nutrition supply, efficient temperature control and an easy-to-clean plant design.

In order to optimize the long-term cost-benefit ratio of the plant, we pay close attention to process economics, with low energy and utility consumption, and high yields, taking into account customer-specific requirements such as the local availability of water.

Proprietary equipment and apparatus

Vogelbusch equipment that can greatly enhance process efficiency includes:

Ultra-efficient fermenter aeration systems

The most suitable aeration system is chosen based on fermentor size, production capacity and available utilities. Three types of tried and tested industrial aeration systems are available for specialized applications.

More about » Aeration systems

Alcohol sensors for process automation

Sensor-equipped analyzers continuously measure the alcohol concentration in the fermenting mash. Gas phase measurement using semiconductor sensors is normally recommended for baker's yeast, but liquid-phase measurement with custom retractable probes is also available.

More about » Gas analyzers

CUSTOMIZED SOLUTIONS

Vogelbusch provides highly specialized services for yeast production plants including

Feasibility studies to determine plant economics
Design, engineering and construction of production plants for fresh and dry yeast
Modernization and revamping of existing yeast production plants to increase capacity, improve yield and/or product quality, and save energy and water
Installation of complete or sectional process control systems
Upgrade of fresh yeast plants to iADY production

Our experts are also available for consultancy services such as strain supply and optimization, and laboratory and pilot plant testing.

Average consumption figures for baker's yeast production

Figures vary considerably depending on raw material, plant capacity and configuration as well as local conditions. To determine specific consumption figures, operating cost and investment cost, a feasibility study can be carried out for your particular case.

Wet yeast

Fermentable monosaccharide per 1,000 kg yeast

Wet (30 % DS)
Sugar consumption	kg	625

Instant active dry yeast (iADY)

Fermentable monosaccharide per 1,000 kg yeast

iADY 96 % DS
Sugar consumption	kg	2,250

Our baker's yeast showcase projects

Yeast plant in Tashkent
CANDY GOLD - Tashkent, Uzbekistan

Following a feasibility study on the production of baker's yeast, the pre-engineering for a yeast plant designed for a daily capacity of 10,000 kg based on molasses was carried out in…

Showcase Projects

Yeast plant in El-Harrach
CEGRO / AYS - El Harrach, Algeria

SGP Cegro on behalf of AYS Algerian Yeast Society in 2014 ordered a feasibility study to investigate the production of 10,000 tons per year of baker's yeast to be made…

Showcase Projects

Yeast plant in Ahvaz
RAZI YEAST & ALCOHOL COMPANY - Ahvaz, Iran

Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from…

Showcase Projects

Yeast fermenter in Hamburg
OHLY (Deutsche Hefewerke) - Hamburg, Deutschland

DHW of Hamburg decided to convert an existing fermenter to the Vogelbusch aeration system. The given situation required the redesign of the drive and included engineering and supply of the…

Showcase Projects

Yeast fermenter in Nuremberg
DEUTSCHE HEFEWERKE - Nuremberg, Germany

DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building.

Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system…

Showcase Projects

Yeast fermenter in Osaka
ORIENTAL YEAST - Osaka, Japan

To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering for an additional yeast fermenter and the supply of key equipment…

Showcase Projects

FAQ

All information given here is based on a standard process and can vary depending on plant configuration. For particular information please send us a message with your project details.

Is there a machine that makes yeast?

No. Yeast is manufactured in a fairly complex processing facility consisting of a range of process units.

Can any molasses be used for baker's yeast production?

No. Only molasses from a sugar FACTORY can be used as it contains not only sugar but also specific substances which are required as nutrient for yeast propagation.

Molasses from a sugar REFINERY (= for conversion of raw sugar into white sugar) can not be used.

Can I also produce fodder yeast in a baker's yeast plant?

It would be technically possible but is uneconomic in operation.

How many hours per day is the plant in operation?

Yeast plants can be operated 24 hours per day, year round. Cycles of five or six days per week are also possible.

What is the minimum capacity for a viable yeast plant?

Technically speaking, a small yeast plant could have a capacity of only 1,000 kg fresh yeast per day. Economically though, this can be recommended only under certain conditions, for instance for own requirements in a bakery.

To remain competitive in trade, the lower limit for an economically feasible production is in the range of 10 to 20 tons per day (wet).

And the investment for such plant?

Capital expenditure strongly depends on plant capacity and configuration as well as local conditions. Costs for the complete process plant (excluding land, buildings, waste water treatment and infrastructure) are from euro 5 million upwards. This figure is for general reference only since each project has its own particularities that need consideration.

Which location is favourable?

Large quantities of drinking water are required in production and subsequently, large volumes of waste water are produced that need treatment.

The plant site therefore has to have a reliable source of potable water and a waste water treatment facility has to be foreseen.

How much space do I need?

For a small sized factory an area of 100 x 75 m is necessary.

How long does it take to set up the plant?

With permits on hand engineering and construction takes 18 - 24 months.

How can I get more information for my yeast plant project?

Complete our design questionnaire (check Links & Downloads section below) and send it back to us to get a professional opinion on your project.