Schematic of DDGS Production

Schematic of DDGS Production
Wheat/Corn/Barley
Fermentation CO 2
Distillation
Ethanol
Thin Stillage
Concentration
Concentrated
Distillers Solubles
(CDS)
Spray Drying
Powdered
Solubles
Whole Stillage
Decanting
Drying (WDG/CDS)
DDGS
Wet Distillers
Grains (WDG)
Drying
Dried Distillers
Grains (DDG)

Characteristics of DWG/DDGS
Feedstock DWG/DDGS Characteristics
100% Corn • Dry granular
• Orange to light brown
• Fermented odour
70% wheat
30%Corn
• Wet cake or crumbs
• Orange and brown
• Fermented odour
100% Wheat • Dry granular
• Deep dark brown
• Fermented odour
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Dried Products (Wheat‐based)
DDGS Air dried Drum dried Freeze dried
DDGS
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Chemical Analysis of DDGS
Cornbased
Wheat/
Cornbased
Wheat‐based
Moisture (%) 9.4 71.4 5.4
Ash (%) 6.1 2.4 4.7
Fat (%) 15.2 10.1 7.3
Protein (%) 30.1 16.1 42.3
Carbohydrate (%) 47.8 71.3 45.3
Dietary Fibre
31.3
43.0
44.4
Energy (calorie/100g)
449
441
418
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Dietary Fibre
100% corn 70% CPS wheat + 30% corn
100% winter wheat 100% CPS wheat
50
45
40
Total dietary fibre (%)
35
30
25
20
15
10
5
0
Raw material DWG DDGS
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Protein
100% corn 70% CPS wheat + 30% corn
100% winter wheat 100% CPS weat
Protein on dry basis (%)
45
40
35
30
25
20
15
10
5
0
Raw material DWG DDGS
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Thin Stillage
• Liquid part of whole stillage
• Rich source of soluble protein and fibre
• Generally concentrated and added back
to distillers grains (DDGS)
• Usual process Evaporation
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Spray Drying
Before
After
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Appearance
•Fine, light beige powder
•Low fermentation taste and smell
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Nutritional Results
Characteristic
(Thin Stillage Powder)
Value (% db)
Moisture 10.9
Protein 41.5
Total Dietary Fibre 21.7
Fat 8.5
Carbohydrates 42.5
Ash 7.4
Energy (Cal/100g) 368
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Properties of Commercial DDGS
Relevant to Food Applications
• High protein
• High fibre
• Colour
• Strong flavour and aroma
• Acidic flavour
• Granular
13

Using DDG or DDGS in Food
Product(s)
Cookies
(Chocolate Chip,
Molasses, Spice,
Sugar)
Bread
(White, Whole
wheat, Banana,
Pumpkin, Carrot‐
Coconut, Sally
Lund)
Existing Research
DDG, DDGS Amount
Source
Barley,
Sorghum,
Wheat, Corn,
Rye
Barley,
Sorghum,
Wheat, Corn,
Rye
Reference
8 –50% Brochetti et al 1989
Morad et al 1984
Rasco et al 1987,
1989,1990
Tsen et al 1982
5 – 40% Brochetti et al 1991
Eidet et al 1984
Morad et al 1984
O’Palka 1989
Rasco et al 1987
Rasco & Dong 1991
Tsen et al 1982, 1983
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Using DDG or DDGS in Food
Existing Research
Product(s)
Rolls
(Dinner, Nut,
Cinnamon)
Muffins
(Corn, Oatmeal,
Wheat)
DDG, DDGS
Source
Barley, Wheat,
Corn, Rye
Barley, Wheat,
Corn, Rye
Amount
Reference
17‐25% O’Palka 1989
Rasco et al 1989
15‐36%
Abbot et al 1991
Brochetti & Penfield
1989
O’Palka 1989
Reddy et al 1986
Pasta
Wheat
25–50%
Maga & van Everen,
1988
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Objectives of Product
Development at FDC
• Incorporate ethanol co‐products into a
variety of food products
• Identify the maximum levels
• Assess the effect on the product’s
sensory and nutritional properties
• Optimize the product formulations
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Products with Wheat‐based DDGS
Product
% Flour
Replaced
Product Quality
Rye Bread 12% • Excellent sensory (taste,
appearance, texture, etc.)
• Achieved “high source of fibre”
claim
Ginger Cookie 30 ‐ 40% • Firmer, drier, crumbly and more
fibrous mouthfeel
• Achieved a “source of fibre” claim
Nutritional Bar 63 ‐ 77% • Darker, acidic, denser and less
sticky bar
• Achieved “source of fibre” claim
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Products with Wheat‐based DDGS
Product
% Flour
Replaced
Product Quality
Peanut Butter Confection 15% • Acidic, drier, firmer and darker
product
• Achieved “source of fibre” claim
Vegetable cracker 25 ‐ 30% • Improved sheeting quality of
dough
• Excellent texture
• Achieved a “source of fibre”
claim
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Issues Affecting DDGS Use in Foods
• Level of yeast cells (high nucleic acid levels)
• Bacteriological quality
• Metal contamination from production
equipment
• Antibiotic residues
• Low lysine content of the protein
• Other established protein and fibre sources
• Feed‐grade raw material
• No Regulatory approval for DDGS
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Debranning
• Debranning is a pre‐milling
treatment which involves selective
removal of the various outer layers
of wheat kernel via the utilization of
friction and abrasion steps
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A Kernel of
Wheat
Endosperm: 83%
‐ Low in lipids, dietary
fibre, minerals, high in
starch
Bran: 14.5%
‐ Rich in dietary fibre,
phytochemicals and
low in starch
Germ: 2.5%
‐ Rich in proteins, lipids,
low in carbohydrates 21

Benefits of Debranning
(Abrasion)
For ethanol industry:
• Removal of non‐fermentable materials
to improve the ethanol production
efficiency
• Utilization of the bran as ingredient in
value‐ added food products (e.g.
nutritional bars, food supplements,
snack products, cereals, nutraceuticals)
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Equipment for Debranning
• Satake abrasive pilot
mill (Model TM‐05C)
• No. 36 abrasive roller
• 1mm slotted screen
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Methods
Debranning
time (sec)
20
Moisture 11.4% Moisture 13.0% Moisture 13.9%
Pearled
Wheat
Wheat
Bran
Pearled
Wheat
Wheat
Bran
Pearled
Wheat
Wheat
Bran
40
60
•Adjusted the moisture content
•Debranning and collecting samples at 20, 40 and 60 sec
•Measure the weight of debranned wheat and bran
•Analyzed for moisture, protein, starch, fibre, fat and ash
contents of debranned wheat and bran
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Wheat Mass Removal
Debranning
time (sec)
Moisture 11.4% Moisture 13.0% Moisture 13.9%
Pearled
Wheat
Wheat
Bran
Pearled
Wheat
Wheat
Bran
• Tempering improves the rate of mass removal
• First abrasion removed 4.4‐6.1% of mass
• Second abrasion removed 3‐4% of mass
• Third abrasion removed 3% of mass
Pearled
Wheat
Wheat
Bran
20 95.6 4.4 94.4 5.6 94.0 6.1
40 92.3 7.7 90.9 9.1 89.2 10.8
60 89.3 10.7 87.6 12.4 86.3 13.7
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Debranning
time (sec)
Removal of Starch
Moisture 11.4% Moisture 13.0% Moisture 13.9%
Pearled
Wheat
0 65.4
Wheat
Bran
Pearled
Wheat
Wheat
Bran
Pearled
Wheat
Wheat
Bran
20 71.9 11.6 67.1 18.5 65.6 17.3
40 69.4 12.8 74.3 21.1 65.3 16.5
60 67.0 17.8 69.4 19.9 69.3 29.0
• Starch content in the bran increased with abrasion time to 29%
after 60 sec
• Tempering increased starch loss
• Moisture and abrasion time to optimize ethanol yield and plant
throughput
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Protein Removal
Abrasion
time(s)
Moisture 11.4% Moisture 13.0% Moisture 13.9%
Pearled
Wheat
0 13.2
Wheat
Bran
Pearled
Wheat
Wheat
Bran
Pearled
Wheat
Wheat
Bran
20 13.0 13.4 13.1 13.6 13.0 13.7
40 12.9 14.3 12.8 14.9 13.0 14.7
60 12.9 15.4 13.0 15.9 12.6 16.0
• Protein content of the bran increased with abrasion time
• Tempering had little effect on protein removal
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Summary
• Industry involvement is needed in research to
facilitate the approval of DDGS in food.
• New ethanol plants must involve regulatory
bodies during design and construction.
• More education and technical support are
needed to help the food industry realize the
benefits of substituting DDGS in formulations.
• Debranning could improve ethanol production
efficiencies while generating co‐products for
use as food ingredients.
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Thank You!
FOOD DEVELOPMENT CENTRE
A Special Operating Agency of Manitoba Agriculture,
Food and Rural Initiatives
P.O. Box 1240, 810 Phillips Street
Portage la Prairie, Manitoba, R1N 3J9
Phone: (204) 239‐3150
Toll‐free: 1‐800‐870‐1044
Fax: (204) 239‐3180
Email: Alphonsus.Utioh@gov.mb.ca
www.gov.mb.ca/agriculture/fdc
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