Adding value to co-productsKeith Waldron.
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
Generalised Production of DDGS
Milling Mashing LiquefactionSaccharifica
tionFermentation
ETHANOLDehydra
tionRectifica
tion
Distillation(steam
injection)
DDGS
Evaporator Thin stillage
DDGWet
distillersgrain
Cereal grains
Decanter
en
zymes
en
zyme
s
yeast
syrup
Variation in DDGS
• Range of producers• Beverage• Fuel ethanol
• Range of grains• Wheat – bran and protein• Barley – glumes, bran and
protein• Maize – bran and protein• Rye - ?
Current use as quality feed
• Traditional use as animal feed• Beef cattle
• Dairy cattle
• Poultry
• Swine
• Fish
• Sheep
• Horses
• Dogs
• Quality Criteria include• Nutrient content:
• Crude protein• Amino acids (lysine
supplementation)• Minerals including phosphorus• Vitamins including water-soluble,
fat soluble (corn), • Biologically active substances e.g.
nucleotides, mannans, glucans, inositol, nucleic acids relevant to immune responses and health
• Metabolisable energy content
• Safety/toxicology (mycotoxins)
• Included in dietary formulationsCONSISTENCY
Deriving higher quality animal feed from 1G ddgs
• Potential to increase protein concentration through fractionation• Importance in e.g. fish feed formulations• Market value of high protein concentrates is much higher –
possibly up to $1000 per tonne?
• Approaches currently being explored• Dry sieving (e.g. Lupitsky et al 2015)• Wet sieving (e.g. Li et al, 2014)• Solubilisation and precipitation (e.g. Chatzifragkou et al
2016).
• Future opportunities• Modification of cereal seed composition through breeding
and biotechnology• Amino acids• Ease of fractionation• Resistance to pests and diseases, reducing levels of mycotoxins etc.
The way forward
• Feed development: Close engagement with animal feed companies relevant to different feed sectors• Ruminants• Non ruminants• Poultry• Aquatic
• Focused research programmes:
in collaboration with• Biotechnology companies• Universities and institutes• National / international
Other opportunities for exploiting
ddgs
• Industrial materials• composites
• Bioenergy• AD
• Ethanol (n.b. fractionation of fibre)
• Lipids for biodiesel
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
Drivers and opportunities for using ddgsfor human food production
Drivers:• Global requirements for more protein• Environmental load from food production• Food v.s Fuel conflict
Opportunities:• Corn DDGS is “gluten free”
• High quality source of protein, no animal fats, low carbohydrate content, high in fibre
• Potentially good for health:
• Diabetes, glycemic index, satiety,
• obesity, colonic health,
• presence of benefical phytosterols.
Challenges to be met
• Legislative: • Compliance with national and international
regulations e.g. FDA (US), FSA (UK) etc.• Safety (mycotoxins, chemicals from process,
allergenicity, etc etc.)
• Novel Foods legislation - in the Eurozone
• Consumer acceptability• Incorporation of a “waste” or “Co-Product” stream!
• Organoleptic quality• Trials with food-grade DDGS from beverage industries – up to 15%
incorporation
• Colouration – darkens product e.g. bread, makes firmer, reduces gluten elasticity; courser and grainier product; extruded snacks and cookies darker also
• Off flavours – from fermentation process and thermal treatments
• Variation in quality due to source of grain etc.
Challenges in meeting the challenges
• Technology• To modulate the biorefining process in order to:
• Control food quality characteristics through process modulation and design and post refinery processing
• Ensure compliance with food regulations
• To develop new food processing approaches and products• In depth evaluation of protein and fibre chemistry and properties,
behaviour as food ingredients, digestibilility and nutrition etc.
• Economic• Cost-benefit analysis of improving the bioethanol process in
order to enhance the food production
• Business models – food processing rather than biorefining!
• Environment• LCA (coupled with LCC)
Generalised Production of DDGS
Milling Mashing LiquefactionSaccharifica
tionFermentation
ETHANOLDehydra
tionRectifica
tion
Distillation(steam
injection)
DDGS
Evaporator Thin stillage
DDGWet
distillersgrain
Cereal grains
Decanter
en
zymes
en
zyme
s
yeast
syrup
GRAIN QUALITYHeavy metal contentPesticidesMycotoxinsDioxinOthersGM traits
Requirement for food-grade processing additives e.g. • Enzymes• Yeasts and yeast propagation media• fermentation additives e.g. urea, ammonia• pH adjusters – acid/alkali etc.
Requirement for food-grade processing aids for example:• anti-foaming agents• antimicrobial agents• Antibiotics• Boiler and distillation antiscaling chemicals etc.
Requirement to address processing use of:• Cleaning solutions• Antifoulers (used in evaporators)• Recycled process water• Salts
DDGS QUALITYConcentration of contaminants from the grain and processing into the DDGS
The Way Forward
Ansoff’s Matrix (circa 1957)
Market Penetration Product Development
Market Development Diversification
Existing Products New Products
Existing Markets
NewMarkets
LOW RISK
MEDIUM RISK
MEDIUM RISK
HIGH RISK
CURRENT DDGS AS A (CHEAP) ANIMAL FEED COMPONENT
IMPROVED DDGS FRACTIONS FOR HIGHER VALUE ANIMAL FEEDS
e.g. DDGS FIBRE FRACTIONS FOR FUEL, ENERGY, MATERIALS ETC
e.g. DDGS FRACTIONS FOR HUMAN FOOD INGREDIENT MARKETS
Substantial research and development – WITH LOW RISK!
• Could be national, but probably needs a pan-European approach, or even global
• Probably appropriate for an EU-style project under the Horizon 2020 programme and beyond.• Biorefining meets food processing……..
• Currently developing discussions• Contact me on [email protected]
The Way Forward
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
biomass
distillation
bioalcohol
Simplified scheme for ethanol production from biomass
PretreatmentAvailable cellulose
hydrolysis sugars
fermentation alcohol
Lignin-rich
residue
CRITERIA FIRST GENERATION SECOND GENERATON
Substrate Grain Lignocellulose
Carbohydrates Starch (and protein) Cellulose (+ pentoses & lignin)
Process Milling, gelatinise, saccharify(thermal amylases) and ferment - easy
Pretreatment (energy), special enzymes (expensive, binding),
Rheology Pumpable Fibrous –difficult to concentrate
Enzyme cost Cheap expensive
Ethanol concentration 12-15% (v/v) 5-7% (v/v) at best. Research = 1-4% (v/v)
Fermentation characteristics
Simple - brewing Problems with fermentation inhibitors, pentose sugars etc
Co-products DDGS, oil etc – adds considerable value, used in well established supply chains.
Hmmm! You can burn the lignin! (after drying!)
Some differences between first and second generation ethanol production
• High energy density cereals
• readily processed using moderate energy and cheap thermally stable enzymes and
• fermented to produce high ethanol concentrations and
• valuable co-product.
• Low energy density material requiring
• energy intensive pretreatments that
• produce fermentation inhibitors,
• requires expensive enzymes that are not thermally tolerant and bind to substrate,
• low substrate concentrations limit resulting ethanol concentrations,
• co-products low in value.• Only benefit – cheap
substrate price
Lignin exploitation (e.g. Borregaard)
Extraction of Vanillin
Pharmaceuticals
Food
Perfumes
Lignin – derived performance chemicals
Concrete additives
Animal feed
Agrochemicals
Oil field chemicals
Soil conditioning
Lignin recovery
(a) Removal of fibre components through hydrolysis
(b) Pulping processes
e.g. Kraft
Soda
Sulfite
Solvent
Horticultural Trials
The way forward
• Idea generation • research programmes in Universities and institutes
• collaboration with the emerging 2G Biorefinery industries and chemical and manufacturing industries.
• PhD funding programmes etc.
• Downstream R&D and translational activities
Conclusions
• Deriving higher quality animal feed from 1G ddgs• Enrich protein and fibre streams respectively• Engage with animal feed companies for joint R&D
• Consideration of potential for human consumption• Develop a new food ingredient and product processing arena • Engage with food researchers, food industries, consumer etc
to meet quality and legislative challenges• Large EU project would be a good start
• Possible routes to valorisation of 2G ddgs.• Fundamental research required to underpin innovative
industrial activities
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