BASF’s proprietary manufacturing process is a key differentiator. The company has optimized their engineering process for consistent protease expression. Their downstream purification employs advanced technologies that minimize impurities and maintain enzyme activity over extended storage and use. This level of control ensures that Lavergy® Pro enzymes maintain high efficacy and batch-to-batch reproducibility—traits essential for formulating high-performance detergents and medical cleaning solutions.
Understanding how enzymes are produced and refined for large-scale detergent use is a key step in choosing the best product for your formulation. The process involved three major steps: fermentation, purification, and stabilization.
In modern enzyme manufacturing, fermentation is executed in controlled stainless-steel bioreactors, where specially selected microorganisms—such as genetically optimized Bacillus or Aspergillus strains—are fed a mix of sugars or agricultural by-products (e.g., corn steep liquor, molasses). Once the fermentation reaches its endpoint, the enzyme-rich liquid is harvested for downstream processing (Cleaning Institute, n.d.).
Variations among manufacturers can include:
- Choice of feedstock: Some use refined sugars, others leverage agro-industrial by-products for cost or sustainability reasons.
- Fermenter scales and control systems: Larger manufacturers may employ advanced monitoring and automation for tighter consistency and higher yields; smaller producers might rely on simpler setups.
- Strain engineering: Proprietary recombinant strains may be used to enhance enzyme expression, specificity, or tolerance to process stresses.
Following fermentation, manufacturers separate the microbial cells from the enzyme-containing broth, typically through filtration or centrifugation. The resultant crude enzyme solution then undergoes purification steps—such as precipitation, ultrafiltration, or chromatography—to remove residual proteins, endotoxins, or other impurities that could impair detergent stability or performance. High quality manufacturers will invest in additional purification steps to reduce impurities that can destabilize detergent formulations (Gürkök, 2019).
Differences across producers might involve:
- Purity standards: Higher-performing products often require more stringent purification, leading to higher costs but yielding greater enzyme stability.
- Technology usage: Some squeeze additional value by combining purification and concentration (e.g., membrane filtration), while others may rely on traditional precipitation or ion exchange.
- Scale effects: Large-scale players can invest in multi-stage purification pipelines; smaller manufacturers may opt for simpler, cost-effective approaches that still meet acceptable performance thresholds.
Once purified, enzymes must be stabilized to survive storage, handling, and the harsh detergent environment. Common approaches include:
- Granulation or Coating: Enzyme powders are often formed into granules or coated with protective layers (e.g., carbohydrate films or polyethylene glycol) to reduce airborne dust (minimizing allergen risk) and shield the proteins from oxygen or moisture.
- Liquid Stabilization: For liquid detergent formulations, enzymes are stabilized in aqueous or semi-aqueous solutions. Additives such as polyols (e.g., glycerol), calcium salts, or borates help maintain activity by preventing denaturation and proteolysis.
- Immobilization & CLEAs: In some industrial contexts, enzymes are immobilized to improve thermal and operational stability, facilitate reuse, and enhance tolerance to harsh conditions. One advanced technique is the formation of Cross-Linked Enzyme Aggregates (CLEAs). In this carrier-free approach, enzyme molecules are precipitated (by agents like ammonium sulfate or PEG), aggregated, and chemically cross-linked—often using glutaraldehyde—to form insoluble and robust biocatalysts that retain high activity and can be reused (Yamaguchi, 2018).
Variability between manufacturers:
- Choice of stabilization strategy: Many detergent enzyme manufacturers focus on granulation or coating for cost efficiency, while specialized or high-end industrial users may adopt immobilization approaches like CLEAs for longevity and recyclability.
- Material additives: Different coatings or film compositions can be proprietary, affecting dust suppression, dispersibility, and shelf stability.
- Use of advanced immobilization: Although less common in everyday detergent production, immobilized formats (e.g., CLEAs) are more prevalent in niche or continuous industrial processes where enzyme reuse is economically beneficial.
With an understanding of how enzymes are sourced, fermented purified, and stabilized, detergent manufacturers can focus on the factors that most directly influence product performance and brand reputation.
The key factors that need to be considered are quality and purity, environmental and safety standards, and innovation and support.
- Prioritize Fermentation Quality: Choose suppliers who use optimized microbial strains and advanced fermenter controls—this ensures consistent enzyme expression and minimizes variability batch-to-batch.
- Demand Rigorous Purification: Impurities can destabilize detergents or trigger unwanted side reactions. High-quality purification—even if costlier—translates into longer shelf life and reliable stain removal.
- Evaluate Stabilization Strategies: Granulation, coating, and liquid stabilization methods differ across manufacturers. Ask for data on dust suppression, oxidation resistance, and long-term activity under real wash conditions.
- Consider Environmental and Safety Standards: Enzymes enable cold-water washing and reduce chemical loads, but occupational safety matters too—seek suppliers who invest in low-dust technologies and transparent handling guidelines.
- Stay Ahead with Innovation and Support:
Leading manufacturers and ingredient distributors–like Barentz–can provide technical data packages, formulation guidance, and next-generation enzymes (e.g., engineered variants for plant-based stains or high-alkaline performance). These partnerships can set your brand apart in a competitive market.
Enzymes are no longer a simple commodity ingredient—they’re a cornerstone of modern, sustainable laundry solutions (Gürkök, 2019). The differences between an average and an exceptional detergent enzyme start long before they reach your blending tanks: in the microbes chosen, the fermentation parameters tuned, the purification rigor applied, and the stabilization methods perfected.
BASF’s Lavergy® Pro line exemplifies how superior enzyme engineering and manufacturing translate into real-world cleaning power. Through molecular optimization and stabilization science, Lavergy® Pro enzymes exhibit higher substrate affinity, improved tolerance to harsh wash chemistries, and extended functional lifespans—all of which lead to greater efficiency for formulators and end-users alike.
Barentz partners with manufacturers like BASF who prioritize strain engineering, thorough quality control, and advanced stabilization, detergent brands can deliver powerful, reliable performance while meeting consumer demand for greener, energy-saving products. In a marketplace where brand loyalty hinges on results and sustainability, partnering with Barentz is an investment in enzyme quality and an investment in your detergent’s reputation and long-term success.
