This document summarizes the industrial production process of riboflavin (Vitamin B2) through fermentation. It describes how the fungus Ashbya gossypii is used in a batch fermentation process to produce around 1000 tons of riboflavin per year. The upstream process involves preparation and sterilization of growth media. Fermentation is followed by downstream processing including harvesting, crystallization, centrifugation and drying to obtain a purified riboflavin powder or granules with 70% purity. Key materials used include glucose, oils and nutrient extracts to feed the fungus, with the major products being riboflavin, biomass and carbon dioxide.

1. Riboflavin–Vitamin B2
Production
MAHYAR M AGHEGH
UNIVERSITY OF TEHRAN – FACULTY OF CHEMICAL ENGINEERING

2. Introduction
• Riboflavin was first isolated by Blyth in 1879 from whey, and
the water-soluble, yellow, fluorescent material was named
lactochrome.
• According to IUPAC rules, riboflavin [83-88-5] is called 7,8-
dimethyl-10-(d-1’-ribityl)isoalloxazine, also known as vitamin
B2 or lactoflavin.
• The daily human demand for riboflavin is around 1.7 mg, and
deficiencies lead to various symptoms such as, e.g., versions of
dermatitis.
• The vitamin cannot be stored in the body and a constant
intake is required.

3. A solution of riboflavin.

4. Introduction
• Chemical synthesis was the first production method to be
established and is still dominating, but in recent years the
production is shifting more and more to fermentation.
• Green plants, most bacteria, and moulds, however, can
produce their own riboflavin.
• At present, three organisms are used for the industrial
production of riboflavin by fermentation:
• The filamentous fungus Ashbya gossypii (BASF, Germany)
• The yeast Candida famata (ADM, USA)
• A genetically engineered strain of Bacillus subtilis (DSM,
Germany)

5. Upstream
Downstream

6. Production Process
• In this case study, a batch process using E. Ashbyii with a capacity of
around 1000 tons/year is analyzed.
• Upstream processing consists of preparation of medium and
associated continuous counter-current sterilization.
• Feed components are: 70% glucose syrup, yeast and malt extract,
sunflower oil, sulfuric acid, and concentrated salt solution at room
temperature.
• Fermentation is operated batch-wise with 10% inoculum ratios.
• Downstream processing starts with harvesting followed by
crystallization, centrifugation (decanter), and final drying (spray
dryer) .
• The requested purity of riboflavin is 70%. The residual 30% consists
of salts and biomass. The product is obtained as dry powder or as
granulate.

7. Upstream
• The upstream processes include preparation and sterilization of the
medium.
• The medium’s composition does not allow sterilization of all
components mixed together and using classical batch conditions
(121◦C, 20 minutes). Therefore, the medium would be divided into
several groups:
I. glucose and sunflower oil,
II. peptone, yeast and malt extracts,
III. salts in water
IV. methionine.
The latter is sterilized by filtration.
Sulfuric acid does not require sterilization.
• Only two separate solutions have to be prepared:
1. 70% glucose (P-1)
2. other nutrients (Nutrients Tank / P-4)

9. Fermentation
• In several steps the necessary seed cultures are prepared in
different seed fermenters.
• The last seed culture is the start inoculum for the main
fermentation.
• The duration of a seed-fermentation is around 50 hours, while
the main fermentation lasts about 500 hours.
• During this time the strain produces 27 g/L riboflavin.
• Fermentation requires aeration accomplished by a gas
compressor (P-7) and a sterile filter (P-8).
• Exhaust gases are filtered by a second filter (P-10).
• A small fraction of the harvested broth is put into another
tank and is used as inoculum for the next batch (P-13).

10. Downstream
• After fermentation the broth is harvested into the harvest
tank (P-15).
• Part of the product crystallizes in the fermenter and also in the
harvesting tank. Crystallization is completed in the crystallizer
(P-16) by evaporation of some of the water.
• Afterwards the suspension is stored in tank P-17.
• From the decanter three streams are harvested, two liquid
phases and the cell/crystal suspension (P-18). To achieve
higher purity, a washing step is used with a second separation.
• The last step is drying, either using a spray dryer to obtain a
powdered product or applying a spray granulation to obtain
granulate. Granulate can be dosed more precisely(P-20)

11. Inventory Analysis
• Air is used for aeration but only a little oxygen is actually
consumed (<1%).
• Nitrogen is inert in this process and passes through the system
unchanged.
• Water is used in the fermentation and in downstream
processing.
• Major organic materials used are sunflower oil, glucose, malt
and yeast extracts, and peptone.
• The major products of the fermentation are riboflavin,
biomass, carbon dioxide, and water.
• Roughly 50% of the carbon used is converted into product,
25% to biomass, and 25% to carbon dioxide.

12. A handful of malted barley,
the white sprouts visible
Viscous yeast extract.

15. Refrences
• Heinzle, Elmar, Arno P. Biwer, and Charles L. Cooney.
Development of sustainable bioprocesses: modeling and
assessment. John Wiley & Sons, 2007.

16. End.