Potential Uses Grains 042007

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POTENTIAL USES FOR

DISTILLERS GRAINS

Compiled by:

John Bonnardeaux

Department of Agriculture and Food

Western Australia

3 Baron-Hay Court

SOUTH PERTH WA 6151

MARCH 2007



DISCLAIMER

While all reasonable care has been taken in the preparation of the material in thisdocument, the Western Australian Government and its officers accept noresponsibility for any errors or omissions it may contain, whether caused bynegligence, or otherwise or for any loss, however caused, sustained by anyperson who relies on it.

© State of Western Australia, 2007



Potential Uses for Distillers Grains

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TABLE OF CONTENTS

1. INTRODUCTION 1 2. BACKGROUND 1 3. ANIMAL NUTRITION 3 4. FOOD USES 6 5. INDUSTRIAL USES FOR DDGS 7 6. CONCLUSIONS 8 7. REFERENCES 9

List of Tables

Table 1. Average percentage of available protein in selected feed supplements 4 Table 2. Essential amino acids profile 4 Table 3. Average price of available protein from selected feed supplements 4 Table 4. Average and range of available energy content* from DDGS, grains and canola

meal for each animal, expressed in MJ/kg, as Metabolizable Energy (ME) for ruminants,Apparent Metabolizable Energy (AME) for poultry and Digestible Energy (DE) for pigs

5 Table 5. Average price of available energy from DDGS, grains and canola meal for

various animal 5 Table 6. Feeding value of DDGS in livestock rations 6

List of Figures

Figure 1. Distillers grains flowchart 2




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1. INTRODUCTION

Distillers grains are produced as a co-product from ethanol production from grain. It is anon-animal based, high protein livestock feed supplement, produced from the distillation anddehydration process during ethanol production.

Ethanol is derived from the fermentation of sugars and starch derived mainly from vegetablematerial such as grain or sugar cane. The fermentation produces alcohol, which can then beblended with petrol or used as a pure fuel in certain engines (these are flexi vehicles and arenot currently available in WA).

Distillers grain can be sold wet or solid: Wet Distillers Grains (WDG), Distillers' Dried Grains(DDG), Distillers' Dried Solubles (DDS) and Distillers' Dried Grains with Solubles (DDGS) areall variations for the co-product from ethanol production and they all vary due to the differenttypes of treatments at the ethanol plant.

In Western Australia, there is the possibility of significant expansion of the ethanol industry inthe next couple of years which could result in a major increase in volume of distillers’ grains.Currently, there is no other industry than the livestock industry to absorb the distillers grains.

With a small feedlot industry in Western Australia, alternative uses and markets for distillersgrains will be necessary when proposed ethanol plants become commercial from 2008onwards. Alternative markets for distillers grains will become important in the future becausethere will be an over-supply of the product which could affect the future viability of the ethanolindustry.

This report examines potential uses for distillers grains, including the livestock and humanconsumption industries and industrial uses.

2. BACKGROUND

Ethanol production from grain involves the conversion of starch to alcohol (ethanol) throughfermentation. The by-products of the fermentation process are wet distillers grains and thinstillage (Figure 1). The difference between these two by-products are:

• Wet distillers grains is made of coarse grain particles.

• The thin stillage contains yeast cells, soluble nutrients and very small grain particles.

Thin stillage is often called distillers solubles. However, this is a misnomer, because much ofthe material is not really soluble, but is instead a suspension of fine particles.




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Fermentation followed byDistillation

Slurry

WHOLE STILLAGE

Option 1: Only the coarse

grain particles are dried

The thin stillage is

evaporated

+

Coarse grain particles

WET DISTILLERS GRAINS

WDG

The whole stillage isscreened and pressedor centrifuged

Liquid fraction

THIN STILLAGE

DRIED DISTILLERS GRAINS

DDG

Condensed thin stillage, syrup-like product

CONDENSED DISTILLERS SOLUBLES

CDS

DRIED DISTILLERS GRAINS

with SOLUBLES

DDGS

Option 2: The coarse grain

particles are dried with the

condensed thin stillage

+

ETHANOL

GRAIN

Figure 1. Distillers grains flowchart




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The two most common versions of distillers grains consumed by the livestock are WetDistillers Grains and Dried Distillers Grains and these are described below:

• Wet Distillers Grains (WDG) contains primarily unfermented grain residues (protein,fibre, fat and up to 70 per cent moisture. WDG has a shelf life of four to five days andinvolves the transport of 70 per cent water by weight of total product. WDG supplytransport is economically viable usually within a 200 km radius from the ethanolproduction facility. These facts are important as they affect both profitability andlogistic issues.

• Dried Distillers Grains with Solubles (DDGS) is WDG that has been dried with theconcentrated thin stillage to 10-12 per cent moisture (Figure 1). DDGS have an almostindefinite shelf life and may be sold and shipped to any market regardless of its vicinityto an ethanol plant. Drying is costly, as it requires the input of further energy.

The conversion rate of grains to ethanol and distillers grains varies with the different types ofgrains and the process used. The details are outlined below:

• The conversion rate of corn to distillers grains is: One tonne of corn produces 378 L ofethanol and 479 kg WDG (70% moisture content), or 309 kg of DDGS (10% moisturecontent).

• The conversion rate of wheat to distillers grains is: one tonne of wheat produces 372 Lof ethanol and 457 kg WDG (70% moisture content), or 295 kg of DDGS (10%moisture content).

The nutrient composition of distillers grains, depends on the type, variety and quality of Drymill ethanol processing creates wet and dry forms of distillers grains. WDG and DDGS arethe two most common versions of distillers grains consumed by the livestock industry:

• WDG is processed grain mash that contains approximately 70 per cent moisture. Wet

distillers grain has a shelf life of 4-5 days and involves the transport of 70 per centwater by weight of total product. Wet distillers grain supply transport is economicallyviable usually within a 200 km radius from the ethanol production facility. These factsare important as they affect both profitability and logistic issues.

• DDGS is WDG that has been dried to 10-12 per cent moisture. DDGS have an almostindefinite shelf life and may be sold and shipped to any market regardless of its vicinityto an ethanol plant. Drying is costly, as it requires the input of further energy. In theUS, it is packaged and traded as a commodity product

3. ANIMAL NUTRITION

The variety of decisions regarding the production and marketing of distillers’ grains are veryimportant for ethanol-producing plants. Next to ethanol, DDGS accounts for the secondlargest source of income for the plant. In the United States (US), DDGS typically makes up10-20 per cent of total income depending on inputs and outputs prices, Federal and Stateincentives, plant size and whether a plant has income from CO2.

The Chairman of Australian Ethanol Ltd stated that: “The future of ethanol in Australia is ingrain alcohol adopting the US model where the fuel ethanol revenue pays the bills and theprofit comes from the distillers’ grain by-product. With a strong cattle industry andcontinuous demand for Australian red meat; fuel ethanol from grain is the future”.




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The nutrient composition of distillers grains, depends on the type, variety and quality of thegrains used, as well as the efficiency of starch conversion and the processing technique.Colour and handling properties of DDGS can also change substantially between

manufacturing plants.

Table 1 illustrates the protein levels in DDGS, different grain types and canola meal. DDGShas the second highest protein content and has a higher protein content that the grain fromwhich it was produced.

Table 1. Average percentage of available protein in selected feed supplements

Feed Unit DDGS Wheat Barley Sorghum LupinsCanolameal

Protein content (range) % DM 30-32 7.5-14.5 20-32 35-37

Protein content (average) % DM 31.00 12.00 11.00 9.00 30.00 36.00

Source: University of Minnesota and the Department of Agriculture and Food, WA (DAFWA).

The chemical composition and amino acid profiles are given in Table 2 for wheat and wheatDDGS. Wheat DDGS has higher amino acid concentrations compared to wheat. Thereforedistillers grains are a valuable source of protein for feed livestock.

Table 2. Essential amino acids profile

Wheat Wheat DDGS

Isoleucine (per cent) 0.363 1.165

Leucine (per cent) 0.719 2.257

Lysine (per cent) 0.321 0.679

Methionine (per cent) 0.178 0.568

Phenylalanine (per cent) 0.505 1.602

Threonine (per cent) 0.540 1.783

Trytophan (per cent) 0.163 0.283

Valine (per cent) 0.475 1.517

Source: International Distillers Grains Conference 2006, Minneapolis.

Table 3 shows the price of grains, DDGS and canola meal per tonne and then converts it to aprice per unit of protein. When comparing the price per unit of protein, DDGS is at least halfthe price of its next competitor. DDGS are not only a valuable source of protein, they are

also the cheapest source of protein (Table 3).Table 3. Average price of available protein from selected feed supplements


Price range $/t 120-130 184-238 160-300 280-400

Average $/t 125 211 181 177 230 345

Protein content(average)

% DM 31.00 12.00 11.00 9.00 30.00 36.00

Protein price(average)

$/kgprotein

0.40 1.76 1.65 1.97 0.77 0.96

Source: University of Minnesota and the Department of Agriculture and Food, WA (DAFWA).




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However, feedlots purchase grain on energy basis − not protein concentration. Table 4shows DDGS contain as much energy as the different grain types particularly for ruminantsand pigs and to a lesser degree broilers.

Table 4. Average and range of available energy content* from DDGS, grains and canola

meal for each animal, expressed in MJ/kg, as Metabolizable Energy (ME) for ruminants,Apparent Metabolizable Energy (AME) for poultry and Digestible Energy (DE) for pigs

Feed DDGS2

Wheat1,5

Barley1,5

Oats1

Triticale1,5

Sorghum1,5

Lupins4

Canolameal

3

Sheep atmaintenance(ME)

12.8-13.7

11.5-13.9

11.2-15.7

12.3-13.4 13.6-14.310.0-13.0

Average ME 15.00 13.25 12.70 13.45 12.85 13.95 11.50 12.20

Cattle ad libitum (ME)

12.2-13.1

12.2-13.2

10.8-13.4

12.9-13.2 10.2-13.1

Average ME 13.72 12.65 12.70 12.10 13.05 11.65 13.00 10.37

Pig DE 14.3-14.8

12.4-15.0

10.6-14.7

0 12.3-16.5 15.5-16.6 12.0-17.0

Average DE 14.60 13.70 12.65 N/A 13.05 14.45 14.50 13.00

Broiler AME8.74-10.11

11.2-14.0

9.9-12.311.3-12.8

9.7-13.0 13.3-14.910.0-10.7

Average AME 9.45 12.60 11.10 12.05 11.35 14.10 10.35 8.36

* All values are based on 90% dry matter.

Source:1GRDC;

2University of Minnesota, US;

3Canola Council of Canada;

4DAFWA;

5Pork CRC.

DDGS also appear to be the most economical energy source for feeding most livestockexcept broilers where sorghum is slightly cheaper (Table 5).

Table 5. Average price of available energy from DDGS, grains and canola meal for variousanimal


Price range $/t 120-130 184-238 160-300 280-400

Average $/t 125 211 181 177 230 345

Sheep atmaintenance

cent/MJ of ME 0.83 1.60 1.43 1.27 2.00 2.83

Cattle ad libitum cent/MJ of ME 0.91 1.67 1.43 1.52 1.77 3.33

Pig DE cent/MJ of DE 0.86 1.54 1.43 1.22 1.59 2.65

Broiler AME cent/MJ of AME 1.32 1.68 1.63 1.26 2.22 4.13

The energy in DDGS is mainly in the form of protein, whereas grains energy are in the formof starch. Protein as a source of energy is less efficient than starch (65%).

When purchasing DDGS, feedlots will need to consider its higher protein content. Excessprotein in the diet increases animal energy utilisation. This is because the animals must useenergy to degrade and excrete the excess protein. Table 6 illustrates the maximum quantityof DDGS that can be fed to livestock.




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Table 6. Feeding value of DDGS in livestock rations

AnimalMax % of DDGS in

rations

Pigs

Nursery Pigs 25%Sows 20-50%

Boars 50%

Poultry

Broilers 10%

Chicken Layers 15%

Turkeys 10%

Ruminants

Dairy Cattle 20%

Beef Cattle 20%

Aquaculture

Catfish up to 20%

Trout up to 8%

Salmon up to 8%

Freshwater Prawns up to 6%

Shrimps up to 5%

Tilapia up to 10%

Source: Dr Jerry Shurson, University of Minnesota’s Department of Animal Science, 2006.

The current price of DDGS, its protein and its energy content, makes DDGS an excellentfeed supplement for livestock.

4. FOOD USES

Distillers grain can also be used for human consumption. There is some research that iscurrently being conducted in this area which is discussed below.

DDGS contain a high concentration of dietary fibre and protein, and have potential forincreased value if used as a flour supplement in baked goods.

A great deal of research was done on DDGS at the Institute for Food Science andTechnology at the University of Washington in the late 1980s. The premise for this was thatfuel ethanol production from wheat could not be profitable unless a high value use, such ashuman food, was found. Distillers grains are chemically and microbiologically safe as a foodingredient. Distillers grains are also high in protein and dietary fibre content and could beused as a high protein and high dietary fibre food ingredient.

In 1987, researchers, Rasco and co-workers at the Institute for Food Science & Technology,University of Washington, in Seattle, substituted 30 per cent of the all-purpose flour in whitebread, whole wheat bread, chocolate chip cookies and banana bread with DDGS. Thecookies and banana bread received ratings from sensory panels that were as good as thosefor the controls containing no DDGS. The breads were rated acceptable to good. WhenDDGS was added to fish batter, replacing 25 per cent of the all-purpose flour, the product

was acceptable to panelists despite the darker colour, and in fact a number of panelistspreferred the yeasty flavour which resulted.




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In 1989, Rasco, McBurney and Edmonds, patented a human food product which theyproduced from DDGS. The primary drawbacks to the utilisation of DDGS in human foodwere smell and taste. A number of researchers had attempted to alleviate these problemswith little success until Rasco and associates developed their process which involvesadjusting the pH of the silage using organic and inorganic acids and neutralisation withselected hydroxides or oxides before drying to a moisture content of 5-10 per cent. Thedrying temperature must be kept low so as not to adversely affect colour or flavour. Theproduct could be used in baked goods such as brownies, cookies, pasta, yeast breads andquick breads at concentrations ranging from 10-50 per cent, depending on the product.

Other researchers looked at the use of dried distiller grains (DDG) in extruded snackproducts. Extrusion cooking involves the cooking of moist starchy or proteinaceous materialsin tubes by a combination of pressure, heat and mechanical shearing (Hauck, 1980). Theextrudate is generally formed by passing it through different shapes of openings in the finaldie. Wheat DDG was found to be one of the more successful materials for extrusion whencompared to corn, oats, barley, rye and sorghum.

Dr Victor Wu and his associates (1984) at the Biopolymer Research Unit, National Centre forAgricultural Utilisation Research (USDA) looked at the by-products formed when hard andsoft wheats and their flours were fermented to produce ethanol. In addition to the energycosts associated with drying silage to concentrate the solubles, they found problems withdenaturation of the protein that could interfere with use in food products. Wu (1987) usedreverse osmosis and ultra-filtration to fractionate the silage into different components, leavinga permeate that could be recycled through the system. The process was less costly thanevaporation and produced a product that had potential for incorporation into foods such asbaked goods.

To date, however, no commercial food products incorporate DDG. In order for viable

products to be successfully manufactured, additional research is needed, especially inmethods for processing DDG into food grade ingredients:

• Pre-treatments such as separation and concentration of proteins, fibres, lipids, or othercompounds.

• Washing, cleaning, and quality upgrading.

• Bleaching, deodorising, and sterilising.

• Milling into flour.

• Development of specific food products such as bakery goods, noodles, pastas, or otherlow carbohydrate, high protein, high fibre foods.

• Storability, shelf life, and preservation assessment; and

• Sensory analysis and acceptability testing.

5. INDUSTRIAL USES FOR DDGS

There has also been research into industrial uses of DDGS for agriculture, fractionation,energy and in the pre-fermentation in the ethanol manufacturing process.

Initial trials to develop value-added applications of DDGS have been conducted in agricultureand included investigating the effects of DDGS applications on soils physical and chemicalproperties. Theoretically, this co-product can be used in agriculture due to its high organic

matter and plant nutrient contents. While DDGS application had positive effects on the




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nitrogen and organic matter contents of the soils, its overall effect on soil fertility wasnegative due to the relatively high levels of sulfur present in DDGS.

Fractionation is a technology that separates grains into fractions, such as fibre, germ andendosperm. In addition, through fractionation, proteins can be extracted from the grain as apre-fermentation step. The technology is gaining momentum in the ethanol industry. Atypical ethanol plant today takes the grain, grinds it into a fine powder and ferments thestarch into ethanol. Everything else − the oil, fibre and protein − ends up in DDGS.Alternatively, fractionation works in a different manner. Only the endosperm is fermented tocreate ethanol, while the remaining fractions are converted into new value-added productssuch as wheat germ oil, used in natural skin care products as a carrier oil. The new processresults in increased ethanol yields and decreased energy consumption.

The distillers grains could also be fed into a biodigester to produce methane gas. Anaerobicdigesters convert solid and liquid biomass wastes by using bacteria operating in anenvironment without the presence of oxygen to produce combustible gas (biogas) similar tonatural gas and a liquid effluent stream containing solids (raw fertiliser) which is used as a

fertiliser.

The breakdown of organic material involves a number of biological steps, each step involvinga well-defined class of bacteria which absorb energy for their survival from graduallydecomposing biomass which is finally converted to water, carbon dioxide and methane. Thebiogas can fuel internal combustion engines driving electrical generators for heat andelectricity.

Depending on the specific composition of the organic material, between 105 and 130 cubicmetres of biogas are produced per tonne of biomass. In energy terms, this corresponds toabout 70 litres of petrol. The anaerobic digestor process enables ethanol plants to be totallyself sufficient for power generation and surplus electricity can be sold to the electricity grid

and are eligible for Renewable Energy Certificates.

The bodies of exhausted bacteria, mixed with organics more difficult to digest such as woodymaterials, constitute the residual digested fertiliser sludge. The sludge is converted to liquidammonia, and potassium and phosphorous fertiliser, all saleable by-products.

6. CONCLUSIONS

With the emerging ethanol industry in Western Australia and indeed the world, there will bean abundance of distillers grains in the coming years. It is currently mainly used as a feedgrain to livestock. However, the livestock industry in WA is small and it will only have thecapacity to consume less than 10 per cent of the total distillers grains potentially produced.

Therefore large surpluses of distiller grains will need to find alternative markets and uses tobe developed.

Distillers grains, in wet or dry form, is a material rich in fibres and proteins. It can beincorporated in baked goods for human consumption although its smell and taste may not beimmediately acceptable to a great majority of consumers.

There are also a range of potential industrial uses for distillers grains. This includes uses asa soil conditioner in agriculture, fractionation where fractions of the grain are utilised in thepre-fermentation process for ethanol production, anaerobic digestion where the distillersgrains is converted into biogas and fertiliser, and re-using the distillers grains with theaddition of enzymes to convert the sugars to starch which can then be used in ethanol

production.




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http://res2.agr.ca/publications/cfar/index_e.htm

http://www.ddgs.umn.edu/

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http://www.iowacorn.org/ethanol/ethanol_17.html

http://www.ddgs.umn.edu/

http://res2.agr.ca/publications/cfar/index_e.htm

Potential Uses Grains 042007

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