Thesis (PhD (Chemical Engineering))--Cape Peninsula University of Technology, 2019 / The South African wine industry is constantly facing several challenges which affect the quality of wine, the local/global demand and consequently the revenue generated. These challenges include the ongoing drought, bush fires, climate change and several liquor amendment bills aimed at reducing alcohol consumption and alcohol outlets in South Africa. It is therefore critical for the wine industry to expand and find alternative ways in which sub-standard or surplus wine grapes can be used to prevent income losses and increase employment opportunities. Traditional Balsamic Vinegar (TBV) is a geographically and legislative protected product produced only in a small region in Italy. However, the methodology can be used to produce similar vinegars in other regions. Balsamic-styled vinegar (BSV), as defined in this thesis, is a vinegar produced by partially following the methods of TBV while applying process augmentation techniques. Balsamic-styled vinegar is proposed to be a suitable product of sub-standard quality or surplus wine grapes in South Africa. However, the production of BSV necessitates the use of cooked (high sugar) grape must which is a less favourable environment to the microorganisms used during fermentation. Factors that negatively affect the survival of the microorganisms include low water activity due to the cooking, high osmotic pressure and high acidity. To counteract these effects, methods to improve the survival of the non-Saccharomyces yeasts and acetic acid bacteria used are essential. The primary aim of this study was to investigate several BSV process augmentation techniques such as, aeration, agitation, cell immobilization, immobilized cell reusability and oxygen mass transfer kinetics in order to improve the performance of the microbial consortium used during BSV production. The work for this study was divided into four (4) phases. For all the phases a microbial consortium consisting of non-Saccharomyces yeasts (n=5) and acetic acid bacteria (n=5) was used. Inoculation of the yeast and bacteria occurred simultaneously. The 1st phase of the study entailed evaluating the effect of cells immobilized by gel entrapment in Ca-alginate beads alongside with free-floating cells (FFC) during the production of BSV. Two Ca-alginate bead sizes were tested i.e. small (4.5 mm) and large (8.5 mm) beads to evaluate the effects of surface area or bead size on the overall acetification rates. Ca-alginate beads and FFC fermentations were also evaluated under static and agitated (135 rpm) conditions. The 2nd phase of the study involved studying the cell adsorption technique for cell immobilization which was carried-out using corncobs (CC) and oak wood chips (OWC), while comparing to FFC fermentations. At this phase of the study, other vinegar bioreactor parameters such as agitation and aeration were studied in contrast to static fermentations. One agitation setting (135 rpm) and two aeration settings were tested i.e. high (0.3 vvm min−1) and low (0.15 vvm min−1) aeration conditions. Furthermore, to assess the variations in cell adsorption capabilities among individual yeast and AAB cells, the quantification of cells adsorbed on CC and OWC prior- and post-fermentation was conducted using the dry cell weight method. The 3rd phase of the study entailed evaluating the reusability abilities of all the matrices (small Ca-alginate beads, CC and OWC) for successive fermentations. The immobilized cells were evaluated for reusability on two cycles of fermentation under static conditions. Furthermore, the matrices used for cell immobilization were further analysed for structure integrity by scanning electron microscopy (SEM) before and after the 1st cycle of fermentations. The 3rd phase of the study also involved the sensorial (aroma and taste) evaluations of the BSV’s obtained from the 1st cycle of fermentation in order to understand the sensorial effects of the Ca-alginate beads, CC and OWC on the final BSV. The 4th phase of the study investigated oxygen mass transfer kinetics during non-aerated and aerated BSV fermentation. The dynamic method was used to generate several dissolved oxygen profiles at different stages of the fermentation. Consequently, the data obtained from the dynamic method was used to compute several oxygen mass transfer parameters, these include oxygen uptake rate ( 𝑟𝑟𝑂𝑂2 ), the stoichiometric coefficient of oxygen consumption vs acid yield (𝑌𝑌𝑂𝑂/𝐴𝐴), the oxygen transfer rate (𝑁𝑁𝑂𝑂2 ), and the volumetric mass transfer coefficients (𝐾𝐾𝐿𝐿𝑎𝑎). During all the phases of the study samples were extracted on weekly intervals to evaluate pH, sugar, salinity, alcohol and total acidity using several analytical instruments. The 4th phase of the study involved additional analytical tools, i.e. an oxygen µsensor to evaluate dissolved oxygen and the ‘Speedy breedy’ to measure the respiratory activity of the microbial consortium used during fermentation. The data obtained from the 1st phase of the study demonstrated that smaller Ca-alginate beads resulted in higher (4.0 g L-1 day−1) acetification rates compared to larger (3.0 g L-1 day−1) beads, while freely suspended cells resulted in the lowest (0.6 g L-1 day−1) acetification rates. The results showed that the surface area of the beads had a substantial impact on the acetification rates when gel entrapped cells were used for BSV fermentation. The 2nd phase results showed high acetification rates (2.7 g L-1 day−1) for cells immobilized on CC in contrast to cells immobilized on OWC and FFC, which resulted in similar and lower acetification rates. Agitated fermentations were unsuccessful for all the treatments (CC, OWC and FFC) studied. Agitation was therefore assumed to have promoted cell shear stress causing insufficient acetification during fermentations. Low aerated fermentations resulted in better acetification rates between 1.45–1.56 g L-1 day−1 for CC, OWC and FFC. At a higher aeration setting, only free-floating cells were able to complete fermentations with an acetification rate of 1.2 g L-1 day−1. Furthermore, the adsorption competence data showed successful adsorption on CC and OWC for both yeasts and AAB with variations in adsorption efficiencies, whereby OWC displayed a lower cell adsorption capability compared to CC. On the other hand, OWC were less efficient adsorbents due to their smooth surface, while the rough surface and porosity of CC led to improved adsorption and, therefore, enhanced acetification rates. The 3rd phase results showed a substantial decline in acetification rates on the 2nd cycle of fermentations when cells immobilized on CC and OWC were reused. While cells entrapped in Ca-alginate beads were able to complete the 2nd cycle of fermentations at reduced acetification rates compared to the 1st cycle of fermentations. The sensory results showed positive ratings for BSV’s produced using cells immobilized in Ca-alginate beads and CC. However, BSV’s produced using OWC treatments were neither ‘liked nor disliked’ by the judges. The SEM imaging results further showed a substantial loss of structural integrity for Ca-alginate beads after the 1st cycle fermentations, with minor changes in structural integrity of CC being observed after the 1st cycle fermentations. OWC displayed the same morphological structure before and after the 1st cycle fermentations which was attributed to their robustness. Although Ca-alginate beads showed a loss in structural integrity, it was still assumed that Ca-alginate beads provided better protection against the harsh environmental conditions in contrast to CC and OWC adsorbents due to the acetification rates obtained on both cycles. The 4th phase data obtained from the computations showed that non-aerated fermentations had a higher 𝑌𝑌𝑂𝑂/𝐴𝐴, 𝑟𝑟𝑂𝑂2 , 𝑁𝑁𝑂𝑂2 and a higher 𝐾𝐾𝐿𝐿𝑎𝑎 . It was clear that aerated fermentations had a lower aeration capacity due to an inappropriate aeration system design and an inappropriate fermentor. Consequently, aeration led to several detrimental biochemical changes in the fermentation medium thus affecting 𝐾𝐾𝐿𝐿𝑎𝑎 and several oxygen mass transfer parameters which serve as a driving force. Overall, it was concluded that the best method for BSV production is the use of cells entrapped in small alginate beads or cells adsorbed on CC under static and non-aerated fermentations. This conclusion was based on several factors such as cell affinity/cell protection, acetification rates, fermentation period and sensorial contributions. However, cells entrapped in Ca-alginate beads had the highest acetification rates. The oxygen mass transfer computations demonstrated a high 𝐾𝐾𝐿𝐿𝑎𝑎 when Ca-alginate beads were used under static-non-aerated conditions compared to fermentations treated with CC. Therefore, a fermentor with a high aeration capacity needs to be designed to best suit the two BSV production systems (Ca-alginate beads and CC). It is also crucial to develop methods which can increase the robustness of Ca-alginate beads in order to improve cell retention and reduce the loss of structural integrity for subsequent cycles of fermentation. Studies to define parameters used for upscaling the BSV production process for large scale productions are also crucial.