Adding value to coproducts. Keith Waldron.

Transcription

1 Adding value to coproducts Keith Waldron.

2 Topics for consideration Deriving higher quality animal feed from 1G ddgs Consideration of potential for human consumption Possible routes to valorisation of 2G ddgs.

3 Topics for consideration Deriving higher quality animal feed from 1G ddgs Consideration of potential for human consumption Possible routes to valorisation of 2G ddgs.

4 Generalised Production of DDGS yeast enzymes enzymes Cereal grains Milling Mashing Liquefaction Saccharifica tion Fermentation ETHANOL Dehydra tion Rectifica tion Distillation (steam injection) DDGS DDG Decanter Wet distillers grain syrup Evaporator Thin stillage

5 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 -?

6 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 CONSISTENCY Safety/toxicology (mycotoxins) Included in dietary formulations

7 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.

8 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

9 Other opportunities for exploiting ddgs Industrial materials composites Bioenergy AD Ethanol (n.b. fractionation of fibre) Lipids for biodiesel

10 Topics for consideration Deriving higher quality animal feed from 1G ddgs Consideration of potential for human consumption Possible routes to valorisation of 2G ddgs.

11 Drivers and opportunities for using ddgs for 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.

12 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.

13 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)

14 Generalised Production of DDGS GRAIN QUALITY Heavy metal content Pesticides Mycotoxins Cereal Dioxin grains Others GM traits ETHANOL DDGS Requirement for food-grade processing additives e.g. Enzymes Yeasts and yeast propagation media fermentation additives e.g. urea, ammonia enzymes ph adjusters acid/alkali etc. Milling Mashing Liquefaction DDG enzymes Saccharifica tion Decanter yeast Fermentation Requirement for food-grade processing aids for example: anti-foaming agents antimicrobial agents Antibiotics Dehydra Boiler and distillation antiscaling Rectifica chemicals etc. tion tion Requirement to address processing use of: Cleaning solutions Antifoulers (used in evaporators) Recycled process water Salts Distillation (steam injection) Wet distillers grain DDGS QUALITY Concentration of contaminants from the syrup grain and processing Evaporator into the DDGS Thin stillage

15 The Way Forward

16 Ansoff s Matrix (circa 1957) Existing Products New Products Existing Markets New Markets Market Penetration CURRENT DDGS AS A (CHEAP) ANIMAL FEED COMPONENT LOW RISK Market Development e.g. DDGS FIBRE FRACTIONS FOR FUEL, ENERGY, MATERIALS ETC MEDIUM RISK Product Development IMPROVED DDGS FRACTIONS FOR HIGHER VALUE ANIMAL FEEDS MEDIUM RISK Diversification e.g. DDGS FRACTIONS FOR HUMAN FOOD INGREDIENT MARKETS HIGH RISK

17 The Way Forward 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 keith.waldron@ifr.ac.uk

18 Topics for consideration Deriving higher quality animal feed from 1G ddgs Consideration of potential for human consumption Possible routes to valorisation of 2G ddgs.

19 biomass Simplified scheme for ethanol production from biomass Pretreatment Available cellulose hydrolysis sugars fermentation alcohol distillation Lignin-rich residue bioalcohol

20 CRITERIA FIRST GENERATION SECOND GENERATON Substrate Grain Lignocellulose Carbohydrates Starch (and protein) Cellulose (+ pentoses & lignin) Process Some differences between first and second generation ethanol production Milling, cereals gelatinise, saccharify (thermal amylases) and ferment - easy Pretreatment pretreatments (energy), that 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 Co-products High energy density readily processed using moderate energy and cheap thermally stable enzymes and fermented to produce Simple high - brewing ethanol concentrations and DDGS, valuable oil etc co-product. adds considerable value, used in well established supply chains. Low energy density material requiring energy intensive produce fermentation inhibitors, requires expensive enzymes that are not thermally tolerant and bind to substrate, low substrate Problems concentrations with fermentation limit inhibitors, resulting pentose ethanol sugars etc concentrations, co-products low in value. Only benefit cheap substrate price Hmmm! You can burn the lignin! (after drying!)

21 Lignin exploitation (e.g. Borregaard) Lignin recovery (a) Removal of fibre components through hydrolysis (b) Pulping processes e.g. Kraft Soda Sulfite Solvent Extraction of Vanillin Pharmaceuticals Food Perfumes Lignin derived performance chemicals Concrete additives Animal feed Agrochemicals Oil field chemicals Soil conditioning

22 Horticultural Trials

23 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

24 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