Sugar alcohols: An overview of manufacturing as a nutritive sweeteners

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1 Sugar alcohols: An overview of manufacturing as a nutritive sweeteners
Osama O. Ibrahim, Ph.D Consultant Biotechnology Gurnee IL.60031 U.S.A.

2 Agenda Most common sugar alcohols. Benefits. Applications.
Manufacturing process. Conclusion.

3 Sugar alcohols Know as sugar relatives.
Naturally occurring in fruits and vegetables. Intermediate metabolites for microbial fermentation and in human body. Produced commercially by chemicals or microbial enzymes via the reduction (hydrogenation) of both mono-saccharides and di-saccharides.

4 Most common sugar alcohols
Derived from mono-saccharides: Xylitol Xylose Sorbitol Glucose Mannitol Fructose Derived from di-saccharides: Isomalt Sucrose Lactitol Lactose Maltitol Maltose

5 Benefits low calorie bulk sweeteners. Provide about 2.5 Kcal/g.
Excellent humactent, texturizing, and anti-crystallizing. Doesn't contribute to the formation of dental decay. May be useful as an alternative to sugars for people with diabetes.

6 General applications Used in a wide variety of products:
- Chocolate products. - Ice cream. - Confectionery. - Chewing gums. - Backed goods.

7 Xylitol 2.4kcal /g. 100% sweetness as sucrose Xylitol metabolism
independently of insulin. [five-carbon polyol]

8 Xylitol production process
Can be produced by chemical or microbial process via the reduction of xylose from xylan rich hemi-cellulose hydrolysate. Xylan rich hemicellulose such as: - Sugar cane baggas. - Rice straw. - Nut shell. - Oat. Sugar cane

9 Chemical process Xylitol are chemically produced from hemi-celluloses via acid hydrolysis. The hemi-cellulose hydrolysate composition are xylose, arabinose, mannose, galactose and glucose. Catalytic hydrogenation in the presence of raney nickel at 1350C and 40 psi for 2.5 hr. Hydrogenation results from hemi-celluloses hydrolysate are: 73 % xylitol, 6 % arabinitol, 9% mannitol, 5% galactitol, and 6.8% sorbitol.

10 Chemical process (Xylitol recovery)
The xylitol can be separated from other sugar alcohols mixture by crystallization. Un-crystallized xylitol can be separated by liquid chromatography method.

11 Microbial direct process
Several xylose utilizing microorganisms can produce xylitol as intermediate metabolite. The microbial pathway of xylose to xylitol is via enzyme xylose reductase in the presence of the co-enzyme NADPH. A number of yeast and filamentous fungi posses this enzyme,such as: - Candida guilliermondii - Candida tropicalis. - Candida pelliculose. - Candida boidinni.

12 Factors effecting the microbial production of Xylitol
Xylose optimum concentration (10%). Presence of other sugars (addition of glucose in the fermentation medium increase xylitol yield). Culture optimum conditions (inoculums size, PH, temperature, aeration, and agitation). Example: - Microbial fermentation of rice straw hydrolysate resulted in bioconversion efficiency of 69%. - Microorganism used fermentation is Candida guillermondii.

13 Microbial indirect process
Isomerization of Xylose to Xyloluse: - Immobilized of Microbial enzyme Xylose isomerase. Converting xyloluse to xylitol: - Microbial fermentation using Mycobacterium smagematise Or - Chemical hydrogenation using catalyst (raney nickel) at 1200C. Xylitol recovery: - Xylitol concentration to 84% solids. - Crystallization of Xylitol.

14 Sorbitol 2.6 kcal/g. 40-70% sweetness of sucrose
Produced on large scale for over fifty years. Total consumption in US., Europe, and Japan 700,000 MT/year. [six- carbon polyol]

15 Production process Can be produced by chemical, enzymatic, or microbial process. Raw materials (substrate) for sorbitol production are glucose or fructose. 1-Chemical process: - Catalytic hydrogenation of glucose or fructose

16 Production process (Cont.)
2- Enzymatic process: (Immobilized system) Glucose Sorbitol Fructose Sorbitol Disadvantage These two enzymes require costly co-factors. Glucose dehydrogenase Bacillus subtilis Sorbitol dehydrogenase Bacillus megaterium

17 Production process (cont.)
3- Fermentation process: - Several mutants of the Genus Zymomonus bacteria are known to produce sorbitol instead of ethanol. - These mutants convert fructose to sorbitol and glucose to gluconic acid. - Conversion efficiency of fructose to sorbitol can be improved in the presence of glucose in fermentation media.

18 Fermentation process (cont.)
- Zymomonus mutants produce the enzyme glucose/fructose trans-hydrogenase as intracellular enzyme. - This enzyme transfer hydrogen atom from glucose to fructose through the co-enzyme NADP. - The gluconic acid produced from glucose can be converted to ethanol via 6-phospho-gluconate pathway.

19 Erythritol Human diet for thousands of years.
Naturally exists in pears, melon, grapes, wine, soy sauce, cheeses and mushrooms. Currently used as a bulk sweetener to reduced calories in foods and beverages. [4 carbon polyol]

20 Production process It can be produced by fermentation using wild osmophillic yeasts such as: Trichosporon, Pichia, Candida, Torulopsis, and Trichosporonoides. All these wild microorganisms can not be applied for production on large scale because it produce glycerol and ribitol as by-products. Microorganisms used commercially are mutants of Aureobasidium sp. Moniliella pollinis and Torula corallina. These industrial mutants do not produce these two by-products of glycerol and ribitol.

21 Optimum fermentation conditions
These mutants under the following conditions are capable to produce up to 20 % erythritol yield and over 49% conversion rate of glucose to erythritol : - Controlling glucose concentration in fed-batch process ( %). - Addition of Cu2+ ( mM) in fermentation media to improve catabolic repression of fumarate from glucose and Co2 (fumarate inhibits the enzyme erythrose reductase). - Adding in the fermentation media inisitol & phytic acid (growth factors) and Mn 2+ (enzymes activator).

22 Erythritol pathway It was found that erythritol is biosynthesized from Fructose- 6 phosphate as follow: Fructose -6-P Erythrose-4-P acetyl- P +H2O Erythrose -4-P Erythrose + ATP Erythrose Erythritol + NADP Transketolase ADP Erythrose reductase NADPH

23 Erythritol Applications
It is Generally Recognized as Safe (GRAS). It has a caloric value of 0.2 calories/ gram. Used as sugar substitutes. Its general applications are as flavor enhancer, formulation aid, humectants, nutritive sweetener, stabilizer and thickener. Its applications in foods are: - Cakes, cookies and bakery fillings. - Hard & soft candies and chewing gum. - Dairy drinks, frozen dairy desserts and yogurt. - Puddings. - Reduced and low-calorie carbonated & non- carbonated beverages.

24 Isomalt - It belongs to the group of disaccharide alcohols.
[12 carbon polyol] - It belongs to the group of disaccharide alcohols. - It is a mixture of gluco-sorbitol and gluco-mannitol. Internationally approved for foods and pharmaceutical applications.

25 Manufacturing process
It is manufactured from sucrose in a two steps process. 1- Enzymatic rearrangement process: Sucrose Isomaltulose 2- Hydrogenation process: 1, ,6 convertase Protaminobacter rubrum Palatinos 1,6 glucopyranosyl-D-sorbitol (GPS) 1000C / 4 bar hydrogen Isomaltulose Raney nickel (GPM) 1,1 glucopyranosyl-D-mannitol

26 Isomalt Applications Isomalt is low caloric sweetener (2 Kcal./g) with unique, excellent tasting sugar-free bulk sweetener. Food products with Isomalt have the same appearance and texture as those made with sugar. It is being used in USA for several years in products such as hard candies, toffees, chewing gum, chocolates, backed goods, nutritional supplements, cough drops and throat lozenges. Currently used in a wide variety of products in Europe and in more than 70 countries.

27 Lactitol It is sugar alcohol derived from di-saccharide lactose.
It is low calorie sweetener with about 40% the sweetness of sugar (sucrose). Used as bulk sweetener for low calorie foods It is also used medically as a laxative.

28 4-O-α-D-Galactopyranosyl-D-glucito
Chemical process 4-O-α-D-Galactopyranosyl-D-glucito

29 Maltitol It is a sugar alcohol derived from di-saccharide maltose.
Has % the sweetness of sugar (sucrose). Produced by hydrogenation of maltose obtained from starch. Used for sugarless hard candies, chewing gum, chocolate, baked goods and ice cream. It is recognized as GRAS in USA.

30 Sugar alcohols as food additives

31 Sugar alcohols applications

32 Global sugar alcohols Market
Sugar alcohols industry grow from ~ $1.9 billion in 2011 to ~$ 2.0 billion in 2012. The market is expected to grow at CAGR (compound annual growth rate) of 7.9 % and reach value ~ $ 3.0 billion by 2017. The biggest consumer market for sugar alcohols are in Europe. Due to the future demand, there are needs to increase sugar alcohols production capacity The major manufacturing bases in the world are China and India.

33 Summary There are a worldwide need for healthy food
products that are lower in calories. The USA consumption of sugar alcohols estimated about 376,640 tons per year. Sorbitol consumption in USA is about 54% of total sugar alcohols. Other sugar alcohols consumption in USA are sharing the 46%. Other sugar alcohols are showing market share increase.