Improving digestibility of feather meal by steam flash explosion

Extraction and improvement of protein functionality using steam explosion pretreatment: advances, challenges, and perspectives

Protein has become an increasingly valuable food component with high global demand. Consequently, unconventional sources, such as industrial and agroindustrial wastes and by-products, emerge as interesting alternatives to meet this demand, considering the UN Sustainable Development Goals and the transition to a circular economy. In this context, this work presents a review of the use of Steam Explosion (SE), a green technique that can be employed as a pretreatment for various waste materials, including bones, hide/leather, feathers, and wool, aimming the extraction of protein compounds, such as low molecular weight biopeptides, gelatin, and keratin, as well as to enhance the protein functionality of grains and meals. The SE technique and the main factors affecting the process's efficiency were detailed. Promising experimental studies are discussed, along with the mechanisms responsible for protein extraction and functionality improvement, as well as the main reported and suggested applications. In general, steam explosion favored yields in subsequent extraction processes, ranging from 27 to 95%, in addition to enhancing solubility and functional protein properties. Nonetheless, it is crucial to maintain the continuity of research on this topic to drive advancements in ensuring the safety of the extracted compounds for use in consumable products and oral ingestion.

Enhanced Biodegradability in Soil of Chicken Feather by Steam Explosion for Potential Application in Agricultural Biodegradable Plastics

Feather waste is a major issue from an economic and environmental point of view. Even though there are already routes for the valorisation of feathers into fertilisers and feather meal, these are considered to have low added value. For more attractive applications, for example in agricultural biodegradable plastics, higher and faster degradability in soil is required. To face this challenge alternative approaches to accelerate biodegradation and disintegration processes are needed. In this context, steam explosion appears as an effective technology to modify the structure of feather and improve its soil degradability. In this work, chicken feathers were treated by steam explosion and the effect of treatment on their structure and physico-chemical and thermal properties were evaluated. Finally, the effect of the process conditions on the disintegration and biodegradation in soil of feathers was also investigated, finding an increased degradation in soil of steam explosion treated feathers. These results open up the possibilities of using feather waste as a component for environmentally friendly agricultural bioplastics that can be degraded in-situ in soil.

Efficient and Green Isolation of Keratin from Poultry Feathers by Subcritical Water

The isolation of keratin from poultry feathers using subcritical water was studied in a batch reactor at temperatures (120-250 °C) and reaction times (5-75 min). The hydrolyzed product was characterized by FTIR and elemental analysis, while the molecular weight of the isolated product was determined by SDS-PAGE electrophoresis. To determine whether disulfide bond cleavage was followed by depolymerization of protein molecules to amino acids, the concentration of 27 amino acids in the hydrolysate was analyzed by GC/MS. The optimal operating parameters for obtaining a high molecular weight protein hydrolysate from poultry feathers were 180 °C and 60 min. The molecular weight of the protein hydrolysate obtained under optimal conditions ranged from 4.5 to 12 kDa, and the content of amino acids in the dried product was low (2.53% w/w). Elemental and FTIR analyses of unprocessed feathers and dried hydrolysate obtained under optimal conditions showed no significant differences in protein content and structure. Obtained hydrolysate is a colloidal solution with a tendency for particle agglomeration. Finally, a positive influence on skin fibroblast viability was observed for the hydrolysate obtained under optimal processing conditions for concentrations below 6.25 mg/mL, which makes the product interesting for various biomedical applications.

Degradation of tannery hide raw trimming hairs using keratinolytic bacteria isolated from tannery effluent-contaminated soil

The disposal of keratinous wastes produced by several leather industries is evolving into a global problem. Around 1 billion tonnes of keratin waste are released into the environment each year. In the breakdown of tannery waste, certain enzymes, such as keratinases produced from microorganisms, might be a better substitute for synthetic enzymes. Keratinase enzymes are able to hydrolyze gelatin, casein, bovine serum albumin and insoluble protein present in wool, feather. Therefore, in this study, bacterial strains from tannery effluent-contaminated soil and bovine tannery hide were isolated and assessed for their ability to produce the keratinolytic enzyme. Among the six isolates, the strain NS1P showed the highest keratinase activity (298 U/ml) and was identified as Comamonas testosterone through biochemical and molecular characterization. Several bioprocess parameters such as pH, temperature, inoculum size, carbon sources, and nitrogen sources were optimized in order to maximize crude enzyme production. The optimized media were used for inoculum preparation and subsequent biodegradation of hide hairs. The degradation efficacy of the keratinase enzyme produced by Comamonas testosterone was examined by degrading bovine tannery hide hairs, and it was found to be 73.6% after 30 days. The morphology of the deteriorated hair was examined using a field emission scanning electron microscope (FE-SEM), which revealed significant degradation. Thus, our research work has led to the conclusion that Comamonas testosterone may be a promising keratinolytic strain for the biodegradation of tannery bovine hide hair waste and the industrial production of keratinases.

A novel chitinous nanoparticles prepared and characterized with black soldier fly (Hermetia illucens L.) using steam flash explosion treatment

This is the first report of the use of steam flash explosion (SFE) to prepare chitinous nanoparticles from black soldier fly (BSF). SFE treatment was performed at a steam pressure of 0.45 to 1.60 MPa with a holding time of 60 s. As the pressure increased, the particle size of the chitinous particles decreased. Under SFE at 1.60 MPa, chitinous nanoparticles with sizes ranging from 59 to 162 nm were produced. SEM, AFM, Raman spectroscopy, FT-IR spectroscopy, ¹H NMR, TGA, and DSC were used to characterize the BSF chitin materials. It was demonstrated that SFE treatment deacetylated chitin to obtain chitosan with 91.24 % deacetylation. In addition, the polymer backbone was maintained, and the degree of polymerization of chitosan nanoparticles was reduced. The activity of the cationic groups of chitosan nanoparticles was improved, thereby enhancing the temperature sensitivity of the polymeric material. It can be concluded that the SFE one-step processing method is a simple and efficient way to prepare homogeneous biomaterial nanoparticles. This study has implications for the development of chitosan nanomaterials for biomedical applications.

Effect of ultrasound on keratin valorization from chicken feather waste: Process optimization and keratin characterization

Chicken feather (CF) has been deemed as one of the main poultry byproducts with a large amount produced globally. However, the robust chemical nature of chicken feathers has been limiting in its wide-scale utilization and valorization. The study proposed a strategy of keratin regeneration from chicken feather combining ultrasound and Cysteine (Cys)-reduction for keratin regeneration. First, the ultrasonic effect on feather degradation and keratin properties was systematically explored based on Cys-reduction. Results showed that the feather dissolution was significantly improved by increasing both ultrasonic time and power, and the former had a greater impact on keratin yield. However, the treatment time over 4 h led to a decrease of keratin yield, producing more soluble peptides, > 9.7 % of which were < 0.5 kDa. Meanwhile, prolonging time decreased the thermal stability with weight loss at a lower temperature and amino acids content (e.g., Ser, Pro and Gly) of keratin. Conversely, no remarkable damage in chemical structure and thermal stability of regenerated keratin was observed by only increasing ultrasonic power, while the keratin solubility was notably promoted and reached 745.72 mg·g^-1 in NaOH (0.1 M) solution (400 W, 4 h). The regenerated keratin under optimal conditions (130 W, 2.7 h, and 15 % of Cys) possessed better solubility while without obvious damage in chemical structure, thermal stability, and amino acids composition. The study illustrated that ultrasound physically improved CF degradation and keratin solubility without nature damage and provided an alternative for keratin regeneration involving no toxic reagent, probably holding promise in the utilization and valorization of feather waste.

Influence of the Degree of Hydrolysis on Functional Properties and Antioxidant Activity of Enzymatic Soybean Protein Hydrolysates

Soybean protein hydrolysates were prepared using two proteolytic enzymes (Alcalase and Protamex) and the degree of hydrolysis (DH) and their functional and antioxidant properties were evaluated. The highest DH value was 20%, with a yield of 19.77% and protein content of 51.64%. The total amino acid content was more than 41% for all protein hydrolysates. The protein hydrolysates from Protamex at pH 2.0 had excellent solubility, emulsifying activity, and foaming capacity, at 83.83%, 95.03 m²/g, and 93.84%, respectively. The water-holding capacity was 4.52 g/g for Alcalase, and the oil-holding capacity was 4.91 g/g for Protamex. The antioxidant activity (62.07%), as measured by the samples' reaction with DPPH (2,2-diphenyl-1-picrylhydrazyl) and the reducing power (0.27) were the strongest for Protamex. An ABTS activity rate of 70.21% was recorded for Alcalase. These findings indicated a strong potential for the utilization of soybean protein hydrolysates to improve the functional properties and antioxidant activity of soybeans as well as their nutritional values.

Valorisation of keratinous wastes: A sustainable approach towards a circular economy

The valorisation of keratinous wastes involves biorefining and recovering the bioresource materials from the keratinous wastes to produce value-added keratin-based bioproducts with a broad application, distribution, and marketability potential. Valorisation of keratinous wastes increases the value of the wastes and enables more sustainable waste management towards a circular bioeconomy. The abundance of keratinous wastes as feedstock from agro-industrial processing, wool processing, and grooming industry benefits biorefinery and extraction of keratins, which could be the optimal solution for developing an ecologically and economically sustainable keratin-based economy. The transition from the current traditional linear models that are deleterious to the environment, which end energy and resources recovery through disposal by incineration and landfilling, to a more sustainable and closed-loop recycling and recovery approach that minimises pollution, disposal challenges, loss of valuable bioresources and potential revenues are required. The paper provides an overview of keratinous wastes and the compositional keratin proteins with the descriptions of the various keratin extraction methods in biorefinery and functional material synthesis, including enzymatic and microbial hydrolysis, chemical hydrolysis (acid/alkaline hydrolysis, dissolution in ionic liquids, oxidative and sulphitolysis) and chemical-free hydrolysis (steam explosion and ultrasonic). The study describes various uses and applications of keratinases and keratin-based composites fabricated through various manufacturing processes such as lyophilisation, compression moulding, solvent casting, hydrogel fabrication, sponge formation, electrospinning, and 3D printing for value-added applications.

A sustainable and efficient recycling strategy of feather waste into keratin peptides with antimicrobial activity

The study aimed to propose an efficient and eco-friendly strategy to improve the utilization of feather waste and converting it into high-valued antimicrobial products. Under the synergistic effect of instant catapult steam explosion (ICSE) (1.5 MPa-120 s), over 90% of chicken feather powder (CFP) was degraded into soluble peptides via keratinolysis within 3 h, about 90% of which were smaller than 3 kDa, indicating an overwhelming advantage than general proteolysis. Importantly, the keratinolysis hydrolysate of CFP was able to inhibit E. coli growth, among which the fraction < 3 kDa exhibited highest antimicrobial activity with a minimal inhibitory concentration of 30 mg/mL. Compared to other fractions, the fraction < 3 kDa contained higher content of hydrophobic amino acids (364.11 mg/g), in which about 79% of peptides had more than 60% hydrophobic ratio, potentially contributing to its antimicrobial activity. ICSE-keratinolysis process holds potential in reducing both protein resource waste and environmental pollution by valorizing feathers into antimicrobial product.

An advanced strategy for efficient recycling of bovine bone: Preparing high-valued bone powder via instant catapult steam-explosion

As the major byproduct of meat processing, bovine bone are produced in large amounts annually. However, the inefficient utilization with low-added value resulted in serious resource waste. The study aims to prepare high-value bovine bone power (BBP) via instant catapult steam-explosion (ICSE) treatment, taking ball milling (BM) method as control. Results showed that ICSE treatment deconstructed bovine bone with more holes emerging, and effectively promoted mineral dissolution and protein degradation while reduced energy consumption. Compared with BM-BBP, ICSE-BBP possessed more protein and essential minerals, presenting in regular elliptical shapes with narrow distribution of particle size (0.1 ∼ 40 μm), and owned better solution stability and protein solubility. ICSE-BBP also exhibited higher mineral release and protein digestibility during GI digestion while revealed no obvious cytotoxicity, indicating the potential applicability in nutrition-fortified foods. Taken together, ICSE technology holds promise in reusing bovine bone, providing an efficient and eco-friendly process for BBP industrial production.

Closing the Loop with Keratin-Rich Fibrous Materials

One of the agro-industry's side streams that is widely met is the-keratin rich fibrous material that is becoming a waste product without valorization. Its management as a waste is costly, as the incineration of this type of waste constitutes high environmental concern. Considering these facts, the keratin-rich waste can be considered as a treasure for the producers interested in the valorization of such slowly-biodegradable by-products. As keratin is a protein that needs harsh conditions for its degradation, and that in most of the cases its constitutive amino acids are destroyed, we review new extraction methods that are eco-friendly and cost-effective. The chemical and enzymatic extractions of keratin are compared and the optimization of the extraction conditions at the lab scale is considered. In this study, there are also considered the potential applications of the extracted keratin as well as the reuse of the by-products obtained during the extraction processes.

Keratin - Based materials for biomedical applications

Keratin constitutes the major component of the feather, hair, hooves, horns, and wool represents a group of biological material having high cysteine content (7-13%) as compared to other structural proteins. Keratin -based biomaterials have been investigated extensively over the past few decades due to their intrinsic biological properties and excellent biocompatibility. Unlike other natural polymers such as starch, collagen, chitosan, the complex three-dimensional structure of keratin requires the use of harsh chemical conditions for their dissolution and extraction. The most commonly used methods for keratin extraction are oxidation, reduction, steam explosion, microbial method, microwave irradiation and use of ionic liquids. Keratin -based materials have been used extensively for various biomedical applications such as drug delivery, wound healing, tissue engineering. This review covers the structure, properties, history of keratin research, methods of extraction and some recent advancements related to the use of keratin derived biomaterials in the form of a 3-D scaffold, films, fibers, and hydrogels.

Assessing the depletion of lincomycin in feathers from treated broiler chickens: a comparison with the concentration of its residues in edible tissues

Lincomycin is the first antimicrobial agent described for the lincosamide class and it is commonly used for the treatment of infectious enteric and respiratory diseases in poultry. Maximum residue limits (MRLs) in edible tissues have been established for this antimicrobial, however, no regulation has been proposed yet for by-products that are not intended for direct human consumption. Feathers are a by-product from poultry farming that might be used as an ingredient for diets fed to other farm animal species. The presence of antimicrobial residues in them is not monitored in spite of the fact that several studies have proved that they can persist in feathers. Currently though, no evidence has been presented regarding the behaviour of lincomycin in this matrix. Hence, this work intended to assess the depletion of lincomycin residues in feathers of birds treated with therapeutic doses and compare them with those detected in muscle and liver samples. Samples were collected for several days after ceasing treatment from a group of broiler chickens treated with a 25% lincomycin formulation. Methanol and Florisil® columns were used to extract and retain the analyte, and samples were analysed using a triple quadrupole mass spectrometer (API 5500, AB SCIEX™). On day 1 after ceasing treatment, average concentrations of lincomycin detected in feather samples reached up to 8582 μg kg^-1 and by day 16, these had only declined by 63%, to an average of 3138 μg kg^-1. Lincomycin residues were detected in feathers at every sampling point, even after they were not detectable in edible tissues. Depletion time was 98 days for feathers, considering the LOQ established for the methodology as cut-off value for the calculations. Data showed that lincomycin is highly persistent in feathers, which may result in this matrix becoming a re-entry route for its residues into the food chain.

Beyond plucking: Feathers bioprocessing into valuable protein hydrolysates

The livestock production and subsequent processing of meat results in huge quantities of solid waste such as viscera, bones, skin and keratin-rich materials, including feathers, hair, wool, claws and hooves. In particular, the continuous growth of poultry industry generates massive amounts of feathers as major waste material. The conversion of such by-products into materials with increased value has been studied. Hydrothermal, chemical or biological approaches have been investigated to achive effective conversion of highly recalcitrant proteins that are abundant in animal waste, but increasing interest is devoted to the development of biotechnological methods. The processing of feathers and other by-products into protein hydrolysates may have industrial and commercial significance. Therefore, this review comprehensively addresses the postulated applications of hydrolysates obtained from keratinous biomasses. Examples on the utilization of feather hydrolysates as organic soil fertilizers, feed ingredients, cosmetic formulations and biofuel production are described in the literature. Microbial feather hydrolysis can generate bioactive peptides as well. The use of protein-rich waste from meat industry to produce hydrolysates with biological activities constitutes a point of utmost interest for development of functional ingredients with elevated value.

Green process to regenerate keratin from feathers with an aqueous deep eutectic solvent

In the present study, waste feathers were processed into uniform keratin feedstock using an aqueous, inexpensive and non-toxic deep eutectic solvent.

In vitro pepsin digestibility and amino acid composition in soluble and residual fractions of hydrolyzed chicken feathers

Beta-keratin in poultry feathers is a structural protein that is resistant to degradation due to disulfide and hydrogen bonds. Feather meal can be a valuable feed compound if the digestibility can be increased. The objective of the present study was to analyze the effects of chemical, enzymatic, and pressure-thermic treatments for chicken feathers on solubility, in vitro protein digestibility (IVPD), and amino acid composition of solubilized and residual fractions. Two experiments were conducted. In experiment 1, models for solubility and IVPD were developed including the above factors applying a central composite face-centered design. Addition of sodium hydroxide (NaOH) and sodium sulfite (Na2SO3), and autoclaving time affected solubility and IVPD of the feather hydrolysates, but not addition of keratinolytic enzyme. In experiment 2, 7 combinations of the hydrolysis factors NaOH, Na2SO3, and autoclaving time with a predicted IVPD of 900 g/kg of DM, calculated for the sum of solubilized and residual feather fractions, were included to measure effects on IVPD and amino acid composition in each fraction. The IVPD values were higher for solubilized than residual fractions when treated with NaOH and autoclaving, but no differences were found when treated with Na2SO3 and autoclaving. Losses of cystine were substantial for all treatments, but lower for Na2SO3 than for NaOH. Furthermore, use of lower Na2SO3 concentration and longer autoclaving time reduced losses of cystine. Compared with NaOH treatments, Na2SO3 gave lower losses of threonine, arginine, serine, and tyrosine. With reference to the ideal protein profile for Atlantic salmon (Salmo salar L.), the treatments with 60 or 90 min autoclaving and 0.36 or 0.21% Na2SO3 had the highest chemical scores. The scores were generally higher for amino acids in residual than solubilized fractions, but with 90 min autoclaving and 0.21% Na2SO3 differences were small. In conclusion, hydrolysis of chicken feathers with low concentrations of Na2SO3 combined with autoclaving results in feather meal with high nutritional value for Atlantic salmon; separation of solubilized and residual fractions is not necessary.

Crystalline reduction, surface area enlargement and pore generation of chitin by instant catapult steam explosion

In this study, instant catapult steam explosion (ICSE) was employed for chitin treatment, and the effect of ICSE on the chitin structure was systematically investigated by using a series of analytical techniques including scanning electron microscopy, X-ray diffraction and Brunauer-Emmett-Teller analysis. Due to the powerful seepage force of the steam during ICSE, the crystallinity index of chitin decreased 10.2% in the (1 1 0) plane and 13.3% in the (0 2 0) plane. Significantly larger surface areas (up to 2.5 times greater, 12.69 m²/g at 1.6 MPa) with more and larger pores (up to a 3.5 times larger pore volume, 0.0333 cm³/g at 2.0 MPa) were achieved after ICSE, and numerous lacerated-like pore shapes were observed on the porous surface of chitin. Importantly, the molecular structure of chitin remained intact with no substantial damage to chitin's molecular weight, thermostability and acetylation (∼70%), which ensures the possibility and diversity of further chitin derivatization.

Keratin: dissolution, extraction and biomedical application

Keratinous materials such as wool, feathers and hooves are tough unique biological co-products that usually have high sulfur and protein contents. A high cystine content (7-13%) differentiates keratins from other structural proteins, such as collagen and elastin. Dissolution and extraction of keratin is a difficult process compared to other natural polymers, such as chitosan, starch, collagen, and a large-scale use of keratin depends on employing a relatively fast, cost-effective and time efficient extraction method. Keratin has some inherent ability to facilitate cell adhesion, proliferation, and regeneration of the tissue, therefore keratin biomaterials can provide a biocompatible matrix for regrowth and regeneration of the defective tissue. Additionally, due to its amino acid constituents, keratin can be tailored and finely tuned to meet the exact requirement of degradation, drug release or incorporation of different hydrophobic or hydrophilic tails. This review discusses the various methods available for the dissolution and extraction of keratin with emphasis on their advantages and limitations. The impacts of various methods and chemicals used on the structure and the properties of keratin are discussed with the aim of highlighting options available toward commercial keratin production. This review also reports the properties of various keratin-based biomaterials and critically examines how these materials are influenced by the keratin extraction procedure, discussing the features that make them effective as biomedical applications, as well as some of the mechanisms of action and physiological roles of keratin. Particular attention is given to the practical application of keratin biomaterials, namely addressing the advantages and limitations on the use of keratin films, 3D composite scaffolds and keratin hydrogels for tissue engineering, wound healing, hemostatic and controlled drug release.

Efficient and eco-friendly extraction of corn germ oil using aqueous ethanol solution assisted by steam explosion

An improved aqueous extraction method has been established for extraction of oil from corn germs. This method primarily included steam explosion pretreatment and aqueous ethanol extraction. Process variables such as steam pressure, resident time, particle size and ethanol concentration were investigated. The highest yield of 93.74 % was obtained when ground steam-exploded corn germ (1.3 MPa, 30 s, 30-35 μm particle size) was treated with 30 % (v/v) aqueous ethanol for 2 h, at 60 °C and pH 9.0. The residual oil content in water and sediment phase decreased dramatically to 4 % and 3 %, respectively. The enhancement mechanism of the process induced by steam explosion was analyzed by confocal laser scanning microscope (CLSM). The quality of extracted crude oil was also investigated. The results showed that the quality of extracted oil was superior to commercial oils.