Changes in mineral concentrations and phosphorus profile during dry-grind processing of corn into ethanol

Substitution of fishmeal: Highlights of potential plant protein sources for aquaculture sustainability

High protein content, excellent amino acid profile, absence of anti-nutritional factors (ANFs), high digestibility and good palatability of fishmeal (FM), make it a major source of protein in aquaculture. Naturally derived FM is at risk due to an increase in its demand, unsustainable practices, and price. Thus, there is an urgent need to find affordable and suitable protein sources to replace FM. Plant protein sources are suitable due to their widespread availability and low cost. However, they contained certain ANFs, deficiency of some amino acids, low nutrient bioavailability and poor digestibility due to presence of starch and fiber. These unfavourable characteristics make them less suitable for feed as compared to FM. Thus, these potential challenges and limitations associated with various plant proteins have to be overcome by using different methods, i.e. enzymatic pretreatments, solvent extraction, heat treatments and fermentation, that are discussed briefly in this review. This review assessed the impacts of plant products on growth performance, body composition, flesh quality, changes in metabolic activities and immune response of fishes. To minimize the negative effects and to enhance nutritional value of plant products, beneficial functional additives such as citric acid, phytase and probiotics could be incorporated into the plant-based FM. Interestingly, these additives improve growth of fishes by increasing digestibility and nutrient utilization of plant based feeds. Overall, this review demonstrated that the substitution of fishmeal by plant protein sources is a plausible, technically-viable and practical option for sustainable aquaculture feed production.

Individual or combinational use of phytase, protease, and xylanase for the impacts on total tract digestibility of corn, soybean meal, and distillers dried grains with soluble fed to pigs

OBJECTIVE

This study was to evaluate the effects of individual or combinational use of phytase, protease, and xylanase on total tract digestibility of corn, soybean meal, and distillers dried grains with soluble (DDGS) fed to pigs.

METHODS

Each experiment had four 4×4 Latin squares using 16 barrows. Each period had 5-d adaptation and 3-d collection. All experiments had: CON (no enzyme); Phy (CON+phytase); Xyl (CON+xylanase); Pro (CON+protease); Phy+Xyl; Phy+Pro, Xyl+Pro, Phy+Xyl+Pro. Each Latin square had 'CON, Phy, Xyl, and Phy+Xyl'; 'CON, Phy, Pro, and Phy+Pro'; 'CON, Pro, Xyl, and Xyl+Pro'; and 'Phy+Xyl, Phy+Pro, Xyl+Pro, Phy+Xyl+Pro'.

RESULTS

The digestible energy (DE), metabolizable energy (ME), and nitrogen retention (NR) of corn were not affected by enzymes but the apparent total tract digestibility (ATTD) of phosphorus (P) was improved (p<0.01) by Phy. The DE and ATTD dry matter (DM) in soybean meal were increased (p<0.05) by Phy+Pro and the ATTD P was improved (p<0.01) by Phy, Phy+Pro, and Phy+Xyl. The DE, ME, and ATTD DM in DDGS were improved (p<0.05) by Phy+Xyl and the ATTD P was improved (p<0.01) by Phy, Phy+Pro, and Phy+Xyl.

CONCLUSION

Phytase individually or in combination with xylanase and protease improved the Ca and P digestibility of corn, soybean meal, and DDGS, from the hydrolysis of phytic acid. The supplementation of protease was more effective when combined with phytase and xylanase in the soybean meal and DDGS possibly due to a higher protein content in these feedstuffs. Xylanase was more effective in DDGS diets due to the elevated levels of non-starch polysaccharides in these feedstuffs. However, when xylanase was combined with phytase, it demonstrated a higher efficacy improving the nutrient digestibility of pigs. Overall, combinational uses of feed enzymes can be more efficient for nutrient utilization in soybean meal and DDGS than single enzymes.

Modeling National Embedded Phosphorus Flows of Corn Ethanol Distillers' Grains to Elucidate Nutrient Reduction Opportunities

Freshwater quality and ecosystem impairment associated with excess phosphorus (P) loadings have led to federally mandated P reduction for certain organic waste streams. Phosphorus reduction from livestock and poultry feeds such as corn ethanol distillers' grains (DGs) presents a centralized strategy for reducing P loss from animal manurein agriculturally intensive states, but little is known about the actual distribution and geospatial P contributions of DGs as animal feed. Here, a county-level flow network for corn ethanol DGs was simulated in the United States to elucidate opportunities for P reduction and the potential for nutrient trading between centralized sources. Overall, the estimated P in DGs that was transferred to US animal feeding operations was nearly twice that present in all human waste prior to treatment. Simulation results suggest that Midwestern states account for an estimated 63% of domestic DG usage, with 72% utilized within the state of production. County-level data were also used to highlight the potential of using nutrient trading markets to incentivize P recovery from DGs at biorefineries within an agriculturally intensive watershed region in Iowa. In summary, corn ethanol biorefineries represent a key leverage point for sustainable P management at the national and local scales.

The Interaction of Dried Distillers Grains With Solubles (DDGS) Type and Level on Growth Performance, Health, Texture, and Muscle-Related Gene Expression in Grass Carp (Ctenopharyngodon idellus)

The aim of this study was to estimate the possible synergetic effects of the two levels of dietary dried distillers grains with solubles (DDGS) from different sources (US-imported and native) on the growth, health status, muscle texture, and muscle growth-related gene expression of juvenile grass carp. Four treatments of fish were fed with 4 isonitrogenous diets, namely, native DDGS20, native DDGS30, US-imported DDGS20, and US-imported DDGS30 for 60 days. The US-imported DDGS30 group showed the better growth and feed efficiency. Additionally, we observed a significant increase in hepatopancreatic total antioxidant capacity (T-AOC) and superoxide dismutase (SOD) in native DDGS groups. Moreover, raw muscle collagen increases considerably in the US-imported DDGS30 compared with the native DDGS30 group. In comparison with the native DDGS groups, the US-imported DDGS groups showed significantly decrease in all textural properties and fiber density, while increased fiber diameter. Dietary native DDGS inclusion significantly showed the upregulation of myog, myhc, and fgf6a expression in muscle, while the downregulation of the expression of myod and myf5. Overall, US-imported DDGS30 had a beneficial influence on growth via regulating genes involved in myogenesis and hypertrophy, the formation of collagen, but had negative impacts on antioxidant capacity and cooked muscle texture.

Phosphorus fractionation and protein content control chemical phosphorus removal from corn biorefinery streams

The economic viability of corn biorefineries depends heavily on the sale of coproducts as animal feeds, but elevated phosphorus (P) contents can exacerbate manure management issues. Phosphorus removal from light steep water and thin stillage, two concentrated in-process aqueous streams at wet milling and dry-grind corn biorefineries, could simultaneously generate concentrated fertilizer and low-P animal feeds, but little is known regarding how differences in stream composition affect removal. To address this data gap, we show that the solubility of P in light steep filtrate (LSF) and thin stillage filtrate (TSF) exhibits distinct sensitivity to calcium (Ca) and base addition due to differences in P fractionation and protein abundance. In LSF, P was primarily organic, and near-complete removal of P (96%) was observed at pH 8 and a Ca/total P (TP) ratio of 2. In TSF, TP removal was lower (81%), and there was more equal distribution of organic and orthophosphate, indicating that the Ca requirements of inorganic P precipitation were a limiting factor. The C/H/N ratio, elemental characterization, and crude protein analysis of the precipitated solids indicated that coprecipitation of amorphous solids containing Ca, Mg, and K with soluble proteins facilitated removal of P, particularly in LSF. Although the removal mechanisms and solubility limits differed, these results highlighted the magnitude (40-70 mM) and efficacy (80-96%) of P recovery from two biorefinery streams.

Advances in yeast alcoholic fermentations for the production of bioethanol, beer and wine

Yeasts have a long-standing relationship with humankind that has widened in recent years to encompass production of diverse foods, beverages, fuels and medicines. Here, key advances in the field of yeast fermentation applied to alcohol production, which represents the predominant product of industrial biotechnology, will be presented. More specifically, we have selected industries focused in producing bioethanol, beer and wine. In these bioprocesses, yeasts from the genus Saccharomyces are still the main players, with Saccharomyces cerevisiae recognized as the preeminent industrial ethanologen. However, the growing demand for new products has opened the door to diverse yeasts, including non-Saccharomyces strains. Furthermore, the development of synthetic media that successfully simulate industrial fermentation medium will be discussed along with a general overview of yeast fermentation modeling.

Toward a Regional Phosphorus (Re)cycle in the US Midwest

Redirecting anthropogenic waste phosphorus (P) flows from receiving water bodies to high P demand agricultural fields requires a resource management approach that integrates biogeochemistry, agronomy, engineering, and economics. In the US Midwest, agricultural reuse of P recovered from spatially colocated waste streams stands to reduce point-source P discharges, meet agricultural P needs, and-depending on the speciation of recovered P-mitigate P losses from agriculture. However, the speciation of P recovered from waste streams via its chemical transformation-referred to here as recovered P (rP) differs markedly based on waste stream composition and recovery method, which can further interact with soil and crop characteristics of agricultural sinks. The solubility of rP presents key tensions between engineered P recovery and agronomic reuse because it defines both the ability to remove organic and inorganic P from aqueous streams and the crop availability of rP. The potential of rP generation and composition differs greatly among animal, municipal, and grain milling waste streams due to the aqueous speciation of P and presence of coprecipitants. Two example rP forms, phytin and struvite, engage in distinct biogeochemical processes on addition to soils that ultimately influence crop uptake and potential losses of rP. These processes also influence the fate of nitrogen (N) embodied in rP. The economics of rP generation and reuse will determine if and which rP are produced. Matching rP species to appropriate agricultural systems is critical to develop sustainable and financially viable regional exchanges of rP from wastewater treatment to agricultural end users.

Purification of Polyphenols from Distiller's Grains by Macroporous Resin and Analysis of the Polyphenolic Components

We aimed to purify polyphenols from distiller’s grain extract using macroporous resins and to identify its polyphenolic components. The influence of operational parameters on purification efficiency was investigated. The polyphenolic composition was analyzed by ultra-performance liquid chromatography tandem mass spectrometry (UPLC-MS/MS) and then quantified by UPLC-MS using authenticated standards. The results showed that the optimal purifying conditions were D101 resin with a dosage of 3 g, four hours adsorption, three hours desorption time, and 60% ethanol as the eluent, producing the highest purification rate of 51%. The purified distiller’s grain extract exhibited stronger antioxidant activity than the unpurified extracts, which was assessed using DPPH and ABTS methods (IC₅₀ DPPH = 34.03 and 16.21 μg/mL, respectively; IC₅₀ ABTS = 20.31 and 5.73 μg/mL, respectively). UPLC-MS results indicated that (−)-epicatechin is the major compound found in distiller’s grain extract which was quantified as 562.7 μg/g extract, followed by ferulic acid (518.2 μg/g), p-hydroxybenzoic acid (417.7 μg/g), caffeic acid (217.1 μg/g), syringic acid (158.0 μg/g) and quercetin (147.8 μg/g). Two compounds, vanillic acid (66.5 μg/g) and gallic acid (41.4 μg/g), were found in lower concentrations. The findings of this study suggest that purification of polyphenolic compounds from distiller’s grain by macroporous resins is feasible, providing a new and effective method for the secondary use of distiller’s grain resources.

Digestibility of amino acids, energy, acid hydrolyzed ether extract, and neutral detergent fiber, and concentration of digestible and metabolizable energy in low-oil distillers dried grains with solubles fed to growing pigs

Two experiments were conducted to test the hypothesis that digestibility of amino acids (AA), gross energy (GE), acid hydrolyzed ether extract (AEE), and neutral detergent fiber (NDF), and values for metabolizable energy (ME) in low-oil distillers dried grains with solubles (DDGS) vary among suppliers. In Exp. 1, the apparent total tract digestibility (ATTD) of GE, AEE, and NDF, and concentration of ME were determined in eight sources of DDGS (sources A, B, C, D, E, G, H, and I). A corn-based basal diet and eight diets containing corn and each source of DDGS were fed to 72 barrows (initial body weight = 18.1 ± 1.3 kg) with eight pigs per diet. Feces and urine were collected for 5 d after 7 d of adaptation. The ME did not differ among the eight sources of DDGS with the exception that DDGS source E contained less (P < 0.05) ME than DDGS source D. The ATTD of GE did also not differ among the eight sources of DDGS, but ME and ATTD of GE in corn were greater (P < 0.05) than in the eight sources of DDGS. However, the ATTD of AEE in corn and the eight sources of DDGS was not different, but the ATTD of AEE in DDGS source E was greater (P < 0.05) than in DDGS source A. The ATTD of NDF in DDGS source D was also greater (P < 0.05) than in DDGS sources E, G, and H, but ATTD of NDF did not differ between corn and the eight sources of DDGS. In Exp. 2, standardized ileal digestibility (SID) of AA was determined in seven sources of DDGS (sources A, B, C, D, E, G, and H). Twenty-four barrows (initial body weight = 63.4 ± 3.4 kg) that had a T-cannula installed in the distal ileum were allotted to a two-period incomplete Latin square design with eight diets. Seven diets were formulated to contain each of the seven sources of DDGS and an N-free diet was also used. Ileal digesta were collected for 2 d after 5 d of adaptation. There were no differences between pigs fed DDGS sources A and B in SID of AA, and the SID of Lys, Met, and Trp did not differ among DDGS sources A, B, and E. However, SID of most indispensable and dispensable AA except Gly were greater (P < 0.05) in DDGS source B than in DDGS sources C, D, E, G, and H. In conclusion, variability in SID of AA, ATTD of NDF and AEE, and ME were observed among the sources of DDGS used in this experiment.

Phytate extraction from coproducts of the dry-grind corn ethanol process

Distiller's dried grains with solubles (DDGSs), the major coproduct of dry-grind ethanol production, are being increasingly used in the global market as animal feeds for both energy and protein supplement.

Evaluation of Selected Nutrients and Contaminants in Distillers Grains from Ethanol Production in Texas

This article contains the results of the evaluation of distillers grain (DG) coproducts from different ethanol plants around the United States and supplemented in animal diets in Texas, based on samples analyzed from 2008 to 2014. The samples were assessed for concentration, occurrence, and prevalence of selected nutrients and contaminants. Protein and sulfur contents of DG were largely different between maize and sorghum coproducts, as well as wet distillers grain with solubles (WDGS) and dried distillers grain with solubles (DDGS), indicating a significant effect of grain feedstock and dry grind process stream on DG composition and quality. Salmonella was isolated in 4 DDGS samples of a total of 157 DG samples, a percentage (2.5%) that is lower than the percentage of Salmonella -positive samples found in other feed samples analyzed during the same period. A small amount of virginiamycin residue was found in 24 maize DDGS, 1 maize WDGS, and 2 sorghum DDGS samples of 242 samples in total. One sorghum DDGS sample of 168 DG samples was contaminated with animal protein prohibited for use in ruminant feed and was channeled to poultry feed. The concentrations of aflatoxin and fumonisin DG coproducts averaged 3.4 μg/kg and 0.7 mg/kg, respectively. Among contaminated maize DG samples, five DDGS samples for aflatoxin contained a higher concentration than the U.S. Food and Drug Administration (FDA) minimum action level of 20 μg/kg for use in animal feed, whereas no sample for fumonisin was found above the action level of 5 mg/kg. The study provides the most current results involving DG coproducts and associated hazards that will assist development of food safety plans required by the FDA in their September 2015 rule titled "Current Good Manufacturing Practice Hazard Analysis and Risk Based Preventive Controls for Food for Animals."

Apparent and standardised ileal amino acid digestibility of wheat distillers dried grains with solubles with or without exogenous protease in broilers and turkeys

The apparent (AIAAD) and standardised ileal amino acid digestibility (SIAAD) of wheat distillers dried grains with solubles (wheat-DDGS) was determined for broilers and turkeys at 28 d using two experiments. A total of 84 male Ross 308 broiler chicks (Experiment 1) or 84 male BUT 10 turkey poults (Experiment 2) were offered a nutrient-adequate diet from d 1 to 23. On d 23, birds in each experiment were allocated to 4 treatments consisting of a nitrogen-free diet (NFD) (with or without protease) and an assay diet containing wheat-DDGS as the only source of amino acids (with or without protease) in a randomised complete block design. In Experiments 1 and 2, the coefficient of AIAAD or SIAAD of Lys and Asp were low irrespective of protease. In Experiment 1, the coefficient of AIAAD ranged from 0.35 (Ala) to 0.75 (Pro) without protease, whereas the range was 0.42 (Thr) to 0.82 (Pro) with protease. Protease improved the coefficient of AIAAD for Arg and Pro and tended to improve the coefficient of AIAAD for Met. Without protease, the coefficient of SIAAD ranged from 0.51 (Ala) to 0.84 (Pro), whereas the range was from 0.65 (Ala) to 0.93 (Pro) with protease. Protease improved the coefficient of SIAAD of Arg, Leu, Phe, Met, Val and Pro. In Experiment 2, the coefficient of AIAAD was lower than 0.50 for all amino acids except for Glu (0.70) and Pro (0.81) without protease. On the other hand, the coefficient of SIAAD ranged from 0.41 (Thr) to 0.89 (Pro) without protease, whereas the range was from 0.56 (Arg) to 0.88 (Pro) with protease supplementation. With the exception of Cys and Pro, protease improved the coefficient of AIAAD and SIAAD of all other amino acids by 0.05-0.19. It was concluded that the AIAAD and SIAAD of wheat-DDGS are variable and are generally greater in broilers compared to turkeys at 28 d of age. Protease improved the ileal digestibility of a large number of amino acids in wheat-DDGS for broilers and turkeys.

Changes in phenolic acid content during dry-grind processing of corn into ethanol and DDGS

BACKGROUND

Nine fractions (1, ground corn; 2, cooked slurry; 3, liquefied slurry; 4, fermented mash; 5, whole stillage; 6, thin stillage; 7, condensed distillers soluble (CDS); 8, distillers wet grains (DWG); and 9, distillers dried grains with solubles (DDGS)) were collected at different steps from three commercial dry-grind bioethanol processing plants. Samples were analyzed for individual and total phenolic acid content by HPLC and the antioxidant capacity by ferric reducing antioxidant power (FRAP) assay.

RESULTS

There were significant differences in phenolic acid (individual and total) content and the antioxidant capacity in the nine fractions collected from the three processing plants, but the changing trends in all three plants were very similar. The four phenolic acids identified in all fractions were caffeic, p-coumaric, ferulic and sinapic acids. Vanillic acid was present in all fractions except fractions 2 and 3. All fractions collected following fermentation, except fractions 6 and 7, had higher concentrations of phenolic acids than fractions before fermentation, with DWG having the highest phenolic acids content.

CONCLUSION

The increased concentration of phenolic acid content after fermentation in four fractions (4, 5, 8 and 9) was primarily due to depletion of starch during dry-grind processing. Further research is needed to investigate the influence of enriched phenolic acid concentration in DDGS on diet palatability (sensory property) and animal health.

Methods to recover value-added coproducts from dry grind processing of grains into fuel ethanol

Three methods are described to fractionate condensed distillers solubles (CDS) into several new coproducts, including a protein-mineral fraction and a glycerol fraction by a chemical method; a protein fraction, an oil fraction and a glycerol-mineral fraction by a physical method; or a protein fraction, an oil fraction, a mineral fraction, and a glycerol fraction by a physicochemical method. Processing factors (ethanol concentration and centrifuge force) were also investigated. Results show that the three methods separated CDS into different fractions, with each fraction enriched with one or more of the five components (protein, oil, ash, glycerol and other carbohydrates) and thus having different targeted end uses. Furthermore, because glycerol, a hygroscopic substance, was mostly shifted to the glycerol or glycerol-mineral fraction, the other fractions had much faster moisture reduction rates than CDS upon drying in a forced air oven at 60 °C. Thus, these methods could effectively solve the dewatering problem of CDS, allowing elimination of the current industrial practice of blending distiller wet grains with CDS for drying together and production of distiller dried grains as a standalone coproduct in addition to a few new fractions.

Phosphorus flow and characterization in dry-grind corn ethanol plants

Both the high phosphorus (P) content and P bioavailability of the animal feed coproducts of the corn-ethanol industry could potentially contribute to increased manure and soil P levels and associated environmental issues (e.g., eutrophication). Therefore, a detailed modeling of total P mass flow to the coproducts (i.e., dry distillers grains with solubles, DDGS) was performed. Distribution of P between inorganic P and phytase-hydrolyzable P forms was quantified for selected coproducts (thin stillage, DDGS, modified DDGS [mDDGS]). The P mass balance indicated that although corn is the major P contributor to the coproducts (80.2%), a substantial portion (19.4%) comes from yeast addition. Of the two components constituting DDGS, wet distillers grains and condensed solubles, the latter contributes to only one-third of the mass but, importantly, yields 70.9% of P. The phytase enzyme used, , was very effective in hydrolyzing the nonorthophosphate P components of thin stillage, DDGS and mDDGS. Our results would help track P movement during various dry-grind processing steps and formulate strategies for phytase enzyme supplementation to various postfermentation coproducts from corn-ethanol plants.

Phytate and other nutrient components of feed ingredients for poultry

Samples of feed ingredients were collected from poultry feed mills in the United States and Canada: corn (133), soybean meal (114), corn distillers dried grains with solubles (DDGS; 89), bakery by-product meal (95), wheat (22), wheat middlings (31), canola meal (21), and wheat shorts (15). The samples were assayed by standard wet chemical techniques for CP, fat, neutral detergent fiber (NDF), acid detergent fiber, calcium, phosphorus, phytate phosphorus, and ash. There was considerable variation found in most of the ingredient components. Forty-two of the 64 CV were above 10.0%. The calcium contents of the ingredients were the most variable, followed by the fat contents. The CP contents were the least variable. There were some fairly consistent relationships observed across samples; in general, acid detergent fiber and NDF were positively correlated, as were ash and mineral levels. Crude protein and fiber levels were positively related, except for wheat shorts, but the relationships were not strong. Phytate P was found to be positively related to ash and total P, as expected, except for corn DDGS. The fat content of corn was found to be negatively related to the NDF content. Significant (P < 0.004) linear regressions were found between phytate P and total P for corn, soybean meal, bakery by-product meal, wheat, wheat middlings, and wheat shorts. The average nonphytate P content of the ingredients was 49.8%, ranging from 38.8% for wheat middlings to 73.2% for DDGS. The phytate P content of wheat and wheat by-products could be predicted from their proximate compositions, with coefficients of determination in excess of 0.740. Predictions for the other ingredients were not as good.

Chemical composition of distillers grains, a review

In recent years, increasing demand for ethanol as a fuel additive and decreasing dependency on fossil fuels have resulted in a dramatic increase in the amount of grains used for ethanol production. Dry-grind is the major process, resulting in distillers dried grains with solubles (DDGS) as a major coproduct. Like fuel ethanol, DDGS has quickly become a global commodity. However, high compositional variation has been the main problem hindering its use as a feed ingredient. This review provides updated information on the chemical composition of distillers grains in terms of nutrient levels, changes during dry-grind processing, and causes for large variation. The occurrence in grain feedstock and the fate of mycotoxins during processing are also covered. During processing, starch is converted to glucose and then to ethanol and carbon dioxide. Most other components are relatively unchanged but concentrated in DDGS about 3-fold over the original feedstock. Mycotoxins, if present in the original feedstock, are also concentrated. Higher fold of increases in S, Na, and Ca are mostly due to exogenous addition during processing, whereas unusual changes in inorganic phosphorus (P) and phytate P indicate phytate hydrolysis by yeast phytase. Fermentation causes major changes, but other processing steps are also responsible. The causes for varying DDGS composition are multiple, including differences in feedstock species and composition, process methods and parameters, the amount of condensed solubles added to distiller wet grains, the effect of fermentation yeast, and analytical methodology. Most of them can be attributed to the complexity of the dry-grind process itself. It is hoped that information provided in this review will improve the understanding of the dry-grind process and aid in the development of strategies to control the compositional variation in DDGS.