Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers...
Transcript of Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers...
![Page 2: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/2.jpg)
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
![Page 3: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/3.jpg)
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
![Page 4: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/4.jpg)
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
![Page 5: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/5.jpg)
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 - ?
![Page 6: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/6.jpg)
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
![Page 7: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/7.jpg)
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.
![Page 8: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/8.jpg)
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
![Page 9: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/9.jpg)
Other opportunities for exploiting
ddgs
• Industrial materials• composites
• Bioenergy• AD
• Ethanol (n.b. fractionation of fibre)
• Lipids for biodiesel
![Page 10: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/10.jpg)
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
![Page 11: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/11.jpg)
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.
![Page 12: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/12.jpg)
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.
![Page 13: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/13.jpg)
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)
![Page 14: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/14.jpg)
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
![Page 15: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/15.jpg)
The Way Forward
![Page 16: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/16.jpg)
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
![Page 17: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/17.jpg)
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
![Page 18: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/18.jpg)
Topics for consideration
• Deriving higher quality animal feed from 1G ddgs
• Consideration of potential for human consumption
• Possible routes to valorisation of 2G ddgs.
![Page 19: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/19.jpg)
biomass
distillation
bioalcohol
Simplified scheme for ethanol production from biomass
PretreatmentAvailable cellulose
hydrolysis sugars
fermentation alcohol
Lignin-rich
residue
![Page 20: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/20.jpg)
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
![Page 21: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/21.jpg)
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
![Page 22: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/22.jpg)
Horticultural Trials
![Page 23: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/23.jpg)
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
![Page 24: Adding value to co- productss3.amazonaws.com/JuJaMa.UserContent/83388493-376f... · distillers grain Cereal grains Decanter s ymes t syrup. Variation in DDGS ... •Ruminants •Non](https://reader034.fdocuments.in/reader034/viewer/2022043005/5f8c0cca16e5ca68b47cbda8/html5/thumbnails/24.jpg)
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